WhiteWolf,
One more question for you...What size ClearPath motors did you decide to use? From the pictures, they look like they might be the CPM-SDSK-3421, but did you use 3421S, 3421D, or 3421P. Using the CNCRP 960 oz-in NEMA 34 motors as a baseline, it looks like the 3421S should be reasonable, but I wanted to check my homework with a classmate. I agree with your choice to use the high-res versions for the R&P drives. You could almost get away with a 3411S for the Z-axis, I would think.
Thanks,
Robert