I'm currently brainstorming the possibility of upgrading my baby 3020 CNC to something a little bit bigger - maybe up to a max of 60 x 40. The idea of recycling some of the components on the existing unit just to get the ball rolling (gantry sides, steppers, spindle mount, spindle, control unit), building a new frame from 30 alu profile, purchasing new ballscrews and upgrading the unsupported bearings to rail sliders is appealing. I've not costed anything yet, but it's probable that it would be cheaper than purchasing the equivalent 6040 unit from Ebay and I'll get a sturdier machine too. I can always beef up the spindle and steppers at a later date if I need the extra grunt and speed. I'll be keen to see whatever work you're currently doing rebuilding yours, @MiKro