• 4 X V Slot 20 x 60 mm 250 mm lengths saw two 500's in half
• 4 X Cast 90 corners
• 8 X M5 10 mm bolts
• 8 X T-Nuts

First i sawed the "500 mm" in half, they're about 496 mm so either have one 250mm and one 244 mm or so, or split the difference

• 4 X M5 8 mm bolts
• 4 X 90 corners
• 4 X T-Nuts

mismatched length, which becomes a problem later so fix it now.

add the cast corners

• 2 X 500 mm extrusions

mark up the center and sides of the Y axis, lay the Y axis over one of the extrusions and mark the sides.

• 6 X M5 8 mm bolts
• 6 X 90 corners
• 14 X T-Nuts

• 2 X 500 mm extrusions

mark front and back beams

• 6 X T-Nuts
• 6 X M5 10 mm bolts

square off and build the frame, this is where you'll see the inaccuracy in the extrusion cuts first i think.

setup both sides of the frame with t-nuts

start squaring it off.

• 4 X M5 x 10 mm bolts

add the backs, i did the four wide facing forward, i am probably going to change the whole thing.

• Y Axis
• 4 X M5 8mm

add the Y axis on top, square it and bolt down the casts, make sure the rear of the front bearing plate is flush with the extrusion, so it is out further than the extrusion towards you, the Y axis end should be flush with the side of the X extrusion.

add the Z axis, its tricky i added the T-Nuts to the casts and put one side in at a time, another pair of hands helps and something to rest the Z on.

the mismatches, all kinds of wrong

obviously i was expecting this,. but i was thinking about changing it out for a column rather than two pieces of 3x1 so a 4x4 or 3x3

Instead of using the self tapping screws for the two top brackets. I tapped the holes with an M4 tap same as the OX, and starting switching out some of the bolts, i recommend changing out the thin pan heads on some spots that are hard to get too because they're easy to wear out, i'm using the nicer machine bolts.

so together for now, i'm going to pull off some of the parts and fix the lengths etc.

with the MDF

With the tool plate (sitting on top of the MDF , which isn't the plan, it'll replace it)

TinyG time..