I kept the base design similar to the original - using a torsion box design. This provides a considerable amount of strength and rigidity with minimum mass. It is important to have a very flat surface to assemble and glue-up the frame. Even with all the care, I ended up in excess of 30 thousandths out of square. This is excellent accuracy for a woodworking project, but it is not all that great for a milling machine.
Taking care at every step means less fine-tuning later. Cut the components carefully, make sure to get the angles as square as possible. Ensure the top (facing downward in these images) is flat-and-true against your flat surface.
Here is the finished torsion box. I changed the design of the x-axis rails - both to provide extra strength and rigidity, and to get the x-axis rails inset just enough to keep them out of the way of most of the dust and debris created during milling.
I kept the base design similar to the original - using a torsion box design. This provides a considerable amount of strength and rigidity with minimum mass. It is important to have a very flat surface to assemble and glue-up the frame. Even with all the care, I ended up in excess of 30 thousandths out of square. This is excellent accuracy for a woodworking project, but it is not all that great for a milling machine.
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