Quote Originally Posted by silyavski View Post
One of the best ways to cut aluminum is to use old fridge compressor that blows cheap airbrush that spays mist of alcohol at the cutter. The mist evaporates instantly and leaves everything dry and cool. So coolant is not a problem.
Cool (no pun intended) idea :) ...

After all your initial input (for which I'm very grateful thanks), here's take 2:

- Z-Axis travel now 100mm (all dims +-)
- Y & Z axis now welded plate (mainly 5mm with 8mm spindle mount plate.
- Used 100x50x4 to mount X and Y-axis rails onto
- Widened guide rail blocks all-round

A pic paints a 1000 words ... so here ya go (2ns is just the Y-bed detail construction):

Click image for larger version. 

Name:	steel-v2.png 
Views:	813 
Size:	259.8 KB 
ID:	13112Click image for larger version. 

Name:	steel-v2-y-bed.png 
Views:	757 
Size:	36.3 KB 
ID:	13111

As always, your feedback valued :)...