Well here goes... Aluminium frame router design

[CharlieRam]

Hi, I did read about the meniscus effect but I am sure I also read that 10mm either side was enough which is why I went for the 80x40, I could lose the 4 inner angle braces and possibly use the spare material to add another cross brace. It is very similar to your design except yours looks a lot stronger, my ballscrew is actually bolted to the front ecocast plate and so 'should' run parallel to the rail front face meaning I only have to adjust up/down, a couple of holes through the box section gantry should enable me to adjust that unless you can get bearing supports that are threaded?
Yes the frame will be heavy but not as heavy as yours, I will need one length of 80x40x4 and 2 lengths of 50x50x3 which I believe will come to just under 120kg, that is without ballscrews etc so should be managable for a couple of people.
I've never welded anything before so I will be practicing first but I have read about spots and little bits at a time so wish me luck on that!
Cheers, Charlie