[Rezort]

Thanks for the reply Zol,
I really did rush into this post so Im stepping it back and starting to all from scratch (taking your advice on board).

Aim: Milling Acrylic Sheets, ABS, Hardwood and some light aluminium sheets (3mm max).
Cutting Area: MIN 300x300x50mm

Frame: 30x60 Aluminium Profile (filled with a sand/epoxy mix where I can)
Controller Kit: Homann Designs (inc 3x 387 steppers)
Rails and Bearings: SBR16-300mm Linear slide rails and Ballscrew RM1204-350mm- c7 (end machined) (might be a gamble in quality but the price is soooo much cheaper than anything else I have found)
Spindle: Probably just an ozito palm router for my first job or 2 (cutting room plaques from the ABS product above)
Budget: ~$1200

Here is the sketch up of the table design (very simple) green is where I hope to fill the extrusion with the sand/epoxy mix to dampen vibrations.
One questionn here, the red areas where the ballscrew feeds through the front and back of the table, can I just over size drill them out (20mm hole) or do I need to use some sort of bearing block in there?



Yes yes first one I attached had the rails not the slides attached to the table >