Wow, sonic, you've been busy! That is certainly going to be one stout carriage! I can't believe you got all that stuff in there - the fit was tight enough in the basic design!
I do have a couple of comments, looking at the pictures - I would get some nylock nuts and use them everywhere. After my table started running, any bolt that had jam nuts would eventually loosen. This was even after I used Locktite (the blue removable one.)
It looks like you've got aluminum pulleys. So do I, but I've had to order some steel ones that go on the steppers - they would work loose, especially on the Z axis, which has to lift the carriage and the router. The steppers have a flat on them, and the set screws were in line with them, but they still worked loose. As soon as they slip you've lost steps, which ruins the work. Trying to tighten them, when there is only 1.5 to 2 threads to hold on to, just doesn't cut it. And yes, this after using the Locktite stuff. I hate set screws. I am going to try the steel pulleys, and if that doesn't do it, I am going to look at pinning the pulley to the stepper shaft.
Although the black pipe might seem rough, since the gantry is rested at four points it evidently gets evened out a bit as it travels. I know the pipe was much straighter than when I started tightening the mounting nuts. Getting them firmly attached without distorting the pipe took me quite a while. Much is made up for by making a constant Z pass with an endmill across your sacrifice board - whatever variation there is in Z as X and Y changes is somewhat compensated by this. I thought about getting some better rod, but that costs lots of dinero, but we can always upgrade to that if need be later.
Anywho, looks like you're doing a great job on your table, and I hope it works like a swiss watch for you!
