Here goes. I ordered a ton of crap, and it should all be here Friday. I should have this thing moving in a week (I am way too optimistic). I am already feeling like I am over my head. But like everything I do, I will figure it out eventually. I do have a few major concerns about software and I would like some help from the experts here.
1) I am proficient in ACad2k, and just installed 2006, but what software is the best and most reasonably priced to convert my files into g code, and then control the router?
2) Has anyone used DeskProto or DeskProto lite? I downloaded a demo, but how can I make sure it can drive my router?
3) I have not figured out how to let the controller know how far it is moving. I know this sounds dumb, but let's say my lead screw is 5 turns per inch, where will I configure the controller?

By the way, I am using xylotex's package.

I will post pictures along with trials and tribulations. I welcome any advice, esp from anyone that has built this plan before.

You can do a lot of things with my macro you asked about, especially if your good with AutoCAD. If you have any questions on how to do something with it, ask in the other forum. As for Deskproto, you might want to look at MeshCAM. It will do about 80-90% of what Deskproto can do for 10% of the price. www.meshcam.com

And for machine control, try Mach3 at www.artofcnc.ca

Will it become obivious to me when I get to the point of turns per inch?

You setup each axis in the control software, (Mach3 or Turbocnc for example) by telling it how many steps it takes to move an axis 1 unit, usually an inch or a mm. For you're example, 200 steps per notor revolution times 8 microsteps per full step (Xylotex default) times 5 turns/ inch.

200 x 8 x 5 = 8000 steps per inch.
Once you tell it it takes 8000 steps per inch, then you can "tune" the motors. Tuning involves a bit of trial and error, slowly increasing speed and acceleration values until you find the useful limit of your steppers, than usually backing off the settings about 20%

Btw, Deskproto won't control a machine, it will just output g-code that the control software will use to run the machine.

I know that was kind of putting the cart before the horse. I have everything in my garage now, and this afternoon, assembly will start . I will post pictures later and hopefully I can provide insight/feedback for people building this plan.

I have cut all the parts out of MDF, and located all holes. One problem I always have accuracy, and I wanted to have these parts burned on a laser. Once I got them, I assembled the x-axis end plates. It was then I realized that I have the wrong bearings. So I had to rotate the x-axis extrusions 90 degress so I could use them. I had a hard enough time finding these on ebay, and I am impatitent and impulsive, so I wasn't waiting any longer to put it together. So I cut another end plate out of MDF and my lack of accuracy strikes again. I reccomend that if you build this plan. Bore one hole (outside one) to spec, and slotting the other slightly. Once you torque the bolts, there is no way they can have any play.

I really like the plans Hack made, and it is hard to imagine building this without them. I will post pictures Monday.

Ok, now that I have the bearings working to my liking, I have the gantry mounted, and will finish the z axis tonight. I will post pictures tomorrow. Wife has had the camera, and I am lazy. ONe mod I have made so far is instead of using 4 bearings on the x axis, I used two of the 6" long ones. I "think" it will be more rigid, and it makes the cutting area a little bigger. This will all become apparent very soon. I also used delrin instead of UHMW, this stuff is so slick, I can't believe it. It should also wear better.