After several years of reading and watching everyone build awesome machines, I am finally getting off my butt to build a CNC machine.

I realized I have a ton of Bed Rails sitting in storage. I tried looking for others that used bed rails but only found one reference here:

http://www.cnczone.com/forums/showthread.php?t=29529

...but I don't want to use any wood. All metal and I need to keep the cost low. I am looking at building a 4' X 4' . I really like how Haydn built his:

http://www.cnczone.com/forums/showthread.php?t=30751

and would like to do something similar. Anyone know how I could incorporate the bed rails into this project??

Isn't it just angle iron?

http://www.mechmate.com/forums/forumdisplay.php?f=6

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your right... man, I am still trying to wake up today...

I think you'll find that bed rail is some pretty hard steel, probably approaching spring steel.
Think about the pounding (no pun intended) it has to take on a nightly basis and keep in mind that some humans have a hoof weight of 300 plus lbs!

Pretty tough stuff. I remember trying to drill hole in some, once upon a time!

Maybe, I could rent a plasma torch and cut through it. I don't want to spend a huge amount of time/frustration doing the basics with the stuff. Though, it sounds like it would be sturdy enough to do the job.

If you use a torch you'll ruin the temper and maybe warp the rails.

You can use a carbide tipped masonry bit, just sharpen it by hand real carefully or you can get 90 degree drill point end mills economically.
check page 23 here
http://www1.mscdirect.com/CGI/NNPDFF?PMCTLG=40&PMPAGE=1

Maybe a dumb question.....what is "bed rail"?

A bed rail is that piece of angle stock that joins the head board to the foot board and supports the springs or box springs.