Help with CNC "router"

[Frenchie461]

This is helpful for the software part assuming that you use AutoCAD, but if you use a 3d program (Inventor or Solidworks) then get Cut2D which is a stripped down version of V-Carve Pro which is what 461 uses. In Vectric's software you have to make a drawing, and then save it as a pdf or dxf and then just assign feed rates and spindle speed (try 3/16 2-flute carbide bit at 2500 rpm and a feed rate of 6-8 inches/minute).

[Thermal]

That's a really heavy duty gantry you got there. Honestly, if you can restore the ballscrew, linear rails/bearings and various other parts you might be able to sell them or the gantry assembly as a whole for a pretty penny and start a CNC router build from scratch using NEMA23's for your steppers. That might be a suitable alternative over working around that behemoth for your application. Ballscrews are real nice but you can get pretty similar performance out of a rack and pinion.

My team has had a real good experience with the Gecko 540 and the pre-fab'd parts from cncrouterparts.com. They're all designed to interface with 8020 or T-slot extruded aluminum.