After a long time I can report little progress. I have received belts and gears from sdp-si. I will mock-up the gear reduction assembly today and have some additional pics for later in the day. I may have to reduce the size of this router due to space but my intention is that it be identical, except in length, to the longer router to which this thread is dedicated.
I have altered my long rails and this will now result in having to weld some parts. I located a small mig welder and when the funds become available I will have it shipped in.
Pic 1: 28 tooth and 72 tooth gears with 1/2" bore. I ordered these gears with a 12mm bore at first, but reordered 1/2" after 12mm stainless steel rod was a bit hard to find. I know I could have gone to a machinist but it would have been probally more expensive in the end. In the end I will use them probably for the second machine so I will pay eventually.
Pic2: 100 tooth pulley belts, 15mm wide. 1/2 bore bearings, 32mm OD, 10mm wide, code 6201-2RS 1/2. I purchased the 12mm bore first and also had to reorder but they were cheap at 1.25 each. They messed up the second order however and sent 7 instead of the 10 I ordered and as my luck would have it I really wanted 8, so I am still 1 short.
I went back to order some more last night and guess what the price more than doubled to 3.26 each.
I cut the bearing holders on my JGRO. The larger one will carry the motor the inside holes will allow me to remove the motor without moving the bearings.
Jason