Well finally after 4 months of hour here and hour there work it's alive!
X = 42"
Y = 26"
Z = 16"
I don't honestly know what size cutting area I ended up with and I haven't had the chance to measure the final size.
Total Build Cost $1400 including router.
THK, IKO Rails - Used from EBay
8020 - Surplus from EBay
Anti-backlash nuts - DumpsterCNC
Solid delrin couplers - DumpsterCNC
1/2-10 TPI Acme Threaded Rod - Enco
Nema35 motor mounts - EBay
280oz/in Nema35 Steppers - Kelinginc
G201 Geckodrives - EBay
Hitachi Router Mount - K2CNC
M12VC Hitachi Router - Lowes
PMDX Breakout Board - PMDX
I'm still in the process of aligning and tuning but i've had it cutting and so far it looks great.
First Cut Video
Second Cut Video