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Just after information about making your own CNC machining to cut balsa, ply and foam. Table size I'm looking for is about 18" x 36" but also maybe something a little bigger. How much would it cost to make something that is capable of only cutting those materials - I'm not interested in making something so strong it can mill metal. I'm looking at spending no more than $1000. Once built, how hard is it to make parts? From my research on the net, some people make it sound really hard and others make it sound easy. People that have already done it , was it worth it? Do you still use your machine?
Thanks

For the size you have specified, $1000 just ain't possible. The motors, drives, and related electronics will go thru $1000 pretty quickly. I am currently in the process of expanding my machine size from X=30" Y= 30" Z=13" up to handle X=53" Y=30" Z=13" and just the commodity material cost has already exceeded $400! (Steel channel, angle, tube, nuts and bolts). And the machine's footprint has grown to a monstrous 55"x80"

You stated that you are "not interested in building something so strong it can mill metal" The truth is, that if it is not, then anything you cut with it is not going to give very good results. Tool path acuracy is directly proportional to machine rigidity. And this comes at a cost, unfortunately. The expanded X axis project I am currently working on, is resulting in my THIRD disassembly, redesign and rebuild of my machine since I began the initial build in 2008.

I am doing some fine-tune modifications during this process, to give the machine some added capabilities. But the biggest thing, is increasing the entire machine's RIGIDITY. Don't get me wrong, it was rigid before..... it's just that the basic frame was built on a light weight 1"x1" tube steel structure that rocked and vibrated as the machine was in use.

This rebuild is resulting in a structure which could literally support an army tank! I won't be happy with the build, until I can grab it by the rails, shake it will all my strength, (with a cup of coffee sitting on the table's surface) and NOT see any ripples occurring in the coffee! I will THEN consider the modification to be a success. Please see the attached MyCNCv1.PDF for a look at the initial build. It contains a lot of information you may find of interest.