Hey Andy,
Good to see you have started your thread and have added some light hearted humour to the forum. Quite entertaining !
I imagine the debate over the axis names is not over
I had an issue trying to get square cuts on the aluminium profile too. Thankfully I bribed a friend and he milled the ends square, (Just as well - they were not pretty)
I can sympathise with you about time and kids. Never enough to time to get the Geeky stuff done....
I look forward to following your entertaining thread....