So having read through some more of this thread (sorry, I've done the book report version so far and read about the first 10 pages and about the last 7 or so) and hoping that some of the original contributors are still monitoring this.

If or should I say, inevitably, when this new board I have coming blows smoke, how easy will it be to replace this with the Gecko G540 controller? Should I stup up for the whole kit? It looks like the Gecko runs at 48V where as the current board runs at 24v.

Though it looks like the motors I have could take it. I have the KL23H286-20-8B steppers.

It looks like there are a few versions and I don't know what would be best. My table is 7' x 12'. the bed and rail frame are steel but the gantry is aluminum.

I can provide pics and info for anything specific you may ask.