K, I've recently developed a need for a full 6" of travel on my taig (or atleast i will after i build a fixture that will hold 4 1.5"x1.5"x12" pieces) and it seems like it should be fairly simple.
All i need are two rectangular spacer blocks, one that extends the stepper mount and one that extends the head assembly. I reason that I already have the extra travel on my lead screw because:
The saddle is 5.5" square. Say the nut is an inch and centered in the saddle, that leaves 2.25 inches of space between the egde to the saddle and the edge of the lead nut. There is only 1.5 inches space between the end of the treads and the Z coulomb, meaning at the end of travel (when the saddle hits the z coulomb, assuming your work fits under the z slide) you still have .75" to go. My half plus a quarter for good measure.
And yes at the other extrema the saddle would protrude the half inch over the gibs, but that should be acceptable? I machine aluminum but the particular application where I need the extra travel is for wood, although i think it would be stable enough for aluminum.
Any opinions?