This is probably not how I will build mine at this time, but one idea I have for the gantry would be like this. Just a rough sketch, but this would probably be one of the best configurations for a gantry. The tool is balanced in the center of gravity instead of cantilevered out to one side. The rails are covered to protect them from chips and dust. The wiring could be contained inside the gantry to keep it safe. Wide stance to keep the lever action on the gantry to a minimum. I added an arch to the design to increase support as you get away from the supported ends.
From the side, you can see where the spindle would ride in this system. Yes, I realize that this looks pretty massive but the structure could be built out of pretty light sheet material. The idea is to increase the section to increase the strength instead of just making the pieces more massive. This expands the distance between the linear motion bearings to stabilize it. It makes it where you have room to build a lift for the z-axis much like the nice router lifts they use in router tables. Making it bigger doesn't increase the mass as much or interfere with the cutting area. Again, the whole idea is to increase stiffness and reduce mass. All the mechanicals could be contained within the gantry and not leave wires hanging out everywhere to catch on things. It would also give the router a finished look instead of just bolted together scrap. If you wanted to build something stronger, you can go to sheet metal and welding. Something lighter could be made from composites.
From the side, you can see where the spindle would ride in this system. Yes, I realize that this looks pretty massive but the structure could be built out of pretty light sheet material. The idea is to increase the section to increase the strength instead of just making the pieces more massive. This expands the distance between the linear motion bearings to stabilize it. It makes it where you have room to build a lift for the z-axis much like the nice router lifts they use in router tables. Making it bigger doesn't increase the mass as much or interfere with the cutting area. Again, the whole idea is to increase stiffness and reduce mass. All the mechanicals could be contained within the gantry and not leave wires hanging out everywhere to catch on things. It would also give the router a finished look instead of just bolted together scrap. If you wanted to build something stronger, you can go to sheet metal and welding. Something lighter could be made from composites.
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