Cheers Neil, understood.

I started looking at things like the Shapeoko, but felt it would be under spec for what I want and my searches here confirm that.

there is a kit on ebay at the moment:

http://www.ebay.co.uk/itm/311266422451

But again, not sure of it's rigidity. I certainly don't want to end up with a slower, less accurate machine that I have.

I'll need to check the spec of the motors that I have, but I'd have though they where lower powered for what I need.

2.5k is well out of budget just now. I'll have to limp along with what I have and hope I can get a few more jobs to justify an upgrade.