The point you bring up about the axis height is a valid one. It seems like that seems to be the biggest design flaw that I’ve seen come up from supporting my end users. I don’t think it’s been show-stopping except in one issue I’ve seen so far, but it’s definitely on my short list of improvements.
To be honest, I wanted to make sure there was enough clearance above the sled top so that the end user could access the router without taking off the machine. There currently is 57mm (2.244in) of clearance between the collet nut and the dust collector window. Especially if a long tool is being used, that’s already not a lot of space to make a tool change. This issue gets complicated by both the ring and the 45* linkage system.
That being said, if we redesigned the spindle clamp so that the router is easily removable, this issue of clearance may be a moot point. I think it’s possible using a 3D printed snap-lock system, similar to the one on the original router base. Of course, that makes the design rely even more heavily on 3D printing.
I have also considered a metal sled as an option to lower the CG of the assembly. I’ve been working on an all-aluminum version off and on, and that’s one of the design considerations. It’s not as easy to get the same weight as the steel one, but I think I have enough aluminum laying around that I could stack a layer or two to bring up the weight.
The anti-backlash nut is something that I’ve looked into. The one I was looking at was a bit different, but it has a similar result. The backlash I’ve measured in the cheaper lead screw nut is pretty minimal, though. It got as much as 0.04mm, which I don’t think is significant enough in the majority of use cases for the machine. If a higher precision is needed than that, though, it’s a easy upgrade to make.
In short, much of the design considerations were made to make it as easy as possible for an end user to make an improved system using the stock Maslow and other tools that makers have common access to. So many of my material choices were made around what materials they would have easy, relatively cheap access to. All aluminum construction would get costly very quickly, both on material costs and time costs. Steel is simply out the realm of what I would consider a workable material for most. Sure, I could plasma cut something but not everyone has easy access to those tools.
Now, if I were able to make some version of an actual product for this, that opens a lot more options. It’s something that I’ve been working on a plan for but haven’t had the time to pursue more.
