This is a rough sketch of the machine I am planning. X axis is planned to be 50” travel, Z axis 3” to 6”, Y axis 16”. However the design may be scaled to suit scrounged components and dollars!
I am inclined to go with a strongly supported cantilever design instead of a moving gantry at this time. As the image indicates, the X Axis is in a vertical frame instead of the more common horizontal design. The Z Axis attaches to the X axis to control the vertical movement, and the Y Axis attaches to the Z Axis to provide cross travel and support the spindle.(router)Some of the work for this machine will require a rotary axis also but the converted 4" rotary table and a tail shaft should be adequate for that.
It is possible that I may have to add a light vertical support and roller going from the free end of the Y Axis to the outside table support however I hope that the design will not require that.
Hopefully this design will give me a high level of precision near the ends of the X Axis travel and with the Spindle near the attached end of the Y Axis while giving a reasonable level of accuracy for 2.5D carving and sign making throughout the travel range.
I am debating making a substantial iron frame to mount the components on or just a heavy base/tabletop mounted combination. Unless someone sees obvious problems the basic design configuration is finalized and it is now a matter of chasing components. The 3x3 and 2x2 square steel tubing is easy to come by and the aluminum will be basic shapes too. That leaves all of the working parts, many of which I will have to find before beginning construction. The X Axis ball screw looks to be the priciest of the parts needed to move the axis so I’ll chase it on E-Bay first. My minimum travel requirements are X=32", Z=3" and Y=12" so I do have some room to work with when shopping for components.
I also plan to retrofit a 14x40 lathe and Bridgeport J-head mill clone in the future so I am inclined to learn how to deal with servo's now. Good idea or should I just use steppers with this design?
Hu