[CarveOne]

jtmullet,

I started homebuilding one of those from the website photos a couple of years ago but didn't finish it. I ran into problems with the rollers not following the rails reliably. I think that it was the rollers I was using since I could not see a clear photo of what the Gemini was using. I redesigned a Copy Carver to use linear bearings and shaft similar to the Gemini (instead of the Copy Carver parallelogram box) and it works fine. I don't do anything with it anymore though, since the CNC router bug bit me.

The distance of the pipe rail above the table isn't very critical. It needs to be roughly in the middle of the expected vertical travel range that you expect to be working with.

The probe distance should be equal to the router bit distance relative to the pivot point. If they are not identical, it will cause the copy object to be shifted by the amount of difference in length. Making the distances the same just insures that the cutter doesn't run off the edge of the workpiece on one end or the other when the workpiece is mounted evenly beside the master template.

The probe tip and cutter tip must be set to the same reference vertically or the copy part's thickness won't be the same as the master object.

Hopefully, someone here can give you the actual dimensions that you requested.

CarveOne