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The best option for long ball screws are driven nuts.
Unfortunately this requires some reconstruction - but this would be the right way to do it.
This is how they work:
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Hey dachopper,
there's one thing that you should consider on your design apart from travel range:
The rails are made of steel and will give you extra bending stability. Especially since you have...

That sounds great!
Keep us posted on your further progress :)

SolidWorks is really great, I love it and I've been working with it for a long time.
I recently had a closer look at Fusion360 and did some projects with it.
Fusion is really great, especially the...

Awkward then. I have one more idea but could be nothing:
Did you try different MDF or a different material in general?
I could imagine something inside some areas of the MDF supporting combustion....

I'm not sure if I'm getting your problem right but screwed parts are not aligned by the screws or exact hole positions.
You have to drill the plates so that you can fit in a screw without problems,...

My homebuilt router has travel-lengths of approx. 24x39" but it should be no problem to extend the long axis to 48".
I have recently digitalized all my plans and drawings, feel free to have a look...

You could do that but I wouldn't as you'd have 25.4 times less accuracy if you don't have more digits on your software. For example Mach3 has a resolution of .001mm by default which equals .00004in....

No, except for being used to imperial units. Calculating with metric units is way easier.

The first thing I'd upgrade are ball-bearings on all axis if it doesn't have them already.

Cheap but...

Hello,
is your feed rate constant during these travels?
I could imagine a decelerating feed rate to be the cause of the burn marks.
You have only encountered these issues with closely-located...