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Here is what I ended up with - https://goo.gl/photos/KX4EChnngmNtH4e18
It's been earning it's keep most days since then, it doesn't look quite as clean now!

No need for nutserts, my Y axis beams...

This is my mk 2, they really don't take much making, been using this one for a while now, works well, one slight change since then, rather than glue the balls in position I just gave them a quick...

Try exporting using R14 format of dxf in corel, I'm using X8 and sheecam and have no problems at all, I know what you mean with the flat spots.

Neat jig!

Yes I get that on stainless and even on ms over 10mm but mines only a powermax 45, what I do is add a slowdown rule in sheetcam, around 2.5 seconds before end set feed rate to 50%, overburn doesn't...

I always like seeing your post's Dave, another top notch job!
It was one of your first builds that gave me the inspiration to build my own machine 3 yrs ago.

Very impressive work there & sleek design, why did you go for a single sided support on the gantry? would you not be safer running rails on both sides?

Thanks Roy,

Think I have most of it here:

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Hi Roy,

I embarked on a similar project 3yrs ago, I set out with the intention on having a bolt together frame for adjustments, I soon realised that a fully welded frame wasn't really a big...

Thanks Eddard, I was the same when building I only had a limited budget and tools.

Only thing I could have done is go a little narrower with the unit, that only came about as I was using the box...

I have found rack/pinion spot on, it wasn't expensive stuff I used, no problems at all.
Have a look at my build here.
https://goo.gl/photos/KX4EChnngmNtH4e18

It works really well, I also cut sheets in half for easier handling, the way I do it is to make up a job in sheetcam with a single line just over the max sheet width, do this for all the thickness's...

You seem to be doing things about 10 times faster than I did, including the fault finding, I'm sure you will make it on time,,,, well done so far!

Well done!
You're flying,,,especially with those speeds!!

It's looking really well in there, very tidy job all round!

I just have the float switch on mine, but mine is a stepper, maybe different for servo I'm not to sure,,I like your bearing mounting position on the gantry, good solid job!

Have you seen mine yet?
https://plus.google.com/u/0/photos/109690725922012077149/albums/5866275352601632753

Mine has side rails that are above the slats, I would do the same again as well, I can...

Aye good move not painting inside I would say, looking good, those gear units look like a good buy, feckin Jaysus it's going to take off at those speeds!! :)

Coming on great, tough work under there I bet.
What are your plans for painting the water tray?
I used a etch primer and then gave it a coat of synthetic , i wouldn't do that again, just a coat of...

Looking good,,,,your'e making good progress!

Fine job!!
I like your 4 jaw chuck design,,,,well done!

Looking great, a lot of stuff to think about at that stage,,,,remember it well :)

Good job, soapy water time!,,,,I used some tractor inner tube on mine, you would think silicone will do the trick though.

Ahh just the ticket! good stuff.

Good stuff, hard to see off the pics,,,,you aren't restricting the flow on the two pipes are you with the cutout are you?
Maybe if you had say 3 legs of 1/2'' bar and raised the pipe 3/4'' up you...

Coming together well! sounds all to familiar with oversize bends :)
I did a video showing my water tank setup,,,,,might be of use to you,,,, I would go for a 2'' air valve min.
...

Oh heck sounds like fun!
I'm not sure about the hot dip, maybe going a bit more than is needed it will last for ages without.
You look like you have a nice flange joint on your tray, looks good!
...

Coming along nicely now Travis, is that the velox z axis I see there? they are a good job although I did take out the 2 springs on mine I felt with the torch weight it made it to stiff.
Ah I bet you...

You soon got to grips with that, nice job the wheel bearing looks right at home in that unit.

It's an option I hadn't thought of before though, thanks for the info.