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Here are some more details on my base/column.

Column is 150mm x 100mm x 10mm, height is 900mm
The base is 3 pieces, the two outer parts are 100mm x 75mm x 10mm, length is 600mm. The center part...

I would encourage you to look at some form of epoxy filler for the steel frame, I built a frame out of heavy steel section for an X2 upgrade and found that while the frame was rigid and allowed heavy...

I bought the 3-Axis NEMA23 350oz servo kit and the Wireless MPG Handwheel from Automation Tech and have been very happy with the purchases.

I will do business with them again if/when the need...

There are two holes that were drilled and tapped into the head, the z axis bearing block is then bolted to the head via these tapped holes.

This pic might be clearer.
...

I have a build thread on another forum of an X2 conversion that might give you some ideas. I cant share the plans as they are copyright, but the photos in the thread might help.

Another X2 Mod...

Delron, have you seen ArcEye's pendant ? http://http://www.mgware.co.uk/ its under the HAL components drop down list.

Regards,

Steve.

I have one of these boxes, the switch is illuminated.

Regards,

Steve.

I have similar hardware, C10 and G320X's, when I first tested my setup it had the same behaviour, swapping the CH-A and CH-B leads on the 320X fixed it for me.

Regards.

Steve.

Yes it does, but you might want to try PyCAM running under pypy. On my i7 I got around a 14x speedup on the carve contour process. (18x with pypy-2.5)

Here's a link to a thread on the linuxcnc...

The closest thing to the G540 would probably be this heatsink with 3 G320X's on it. http://www.geckodrive.com/heatsink.html

Although its only 3 channel and overpriced, it is pre-drilled and...

LOL, color me jealous, I have a low mileage '03 2 door with the 5.7 and always thought it was a bit sporty, the V10 is a big step up in HP and torque. Must be a lot of fun to drive.

P.S.
My...

Beautiful job on the mill housing / chip tray. Is that a RAM in the background ?

Steve.

You're on the right track, you just need to adjust the lock-nuts on the Y- Axis handle to minimize the play while allowing smooth turning of the handle.

Regards.

Steve.

I bought a set of plans in Feb 2014 on a weekend, I didn't get a response for a day or two.

David personalizes the plans with your name and email address at the bottom of each sheet.

I would...

I used acetal nuts on my mini mill conversion, they worked out very well, no backlash. There's a thread here with a lot of info and tips. Making Acetal leadscrew nuts the easy way

Steve.

The column is clamped by 4 long steel plates and 8 bolts, the four plates are inside the original column and the bolts screw in from inside the steel tube.

- Steve.

I did something similar, used some heavy walled tubing to beef up a mini-mill, it worked very well.

Here's a link to some pics of the conversion. Mill Photos by madluther | Photobucket

Regards,...

I used these plans, bought them in February this of year. I didn't go with the stock screws, but they are a solid set of plans.

Regards.

Steve.

The acetal nuts have been pretty good so far, The Y axis nut is a fraction loose and has about .001" of backlash.
The X axis nut is a bit tight and has no backlash at all.
Making them has a bit...

Here's my solution, A bit over the top but the results were excellent.
The link is to a series of photo bucket pics of the upgrade.

Mill Photos by madluther | Photobucket

Regards.

Steve.

If you read the entire linked thread, there is discussion on wear, they last much longer than brass due to the wiping nature of acetal.

Edit, link to the wear entry Making Acetal leadscrew nuts...

I'm about 80% into an x2 conversion using these plans. To answer your backlash question - I went off on different track and tried this.
Making Acetal leadscrew nuts the easy way
So far they have...