Well, the title box wouldn't allow me to finish, but I just started the build of my first of what I hope to be many CNC Plasma tables. This is a smaller, entry level table, designed with a 2' x 3' travel, plus the ability to accommodate full size sheets, due to the unique design of the carriage. The chassis is the main welded component of the assembly. It is made of 2" square tubing with a 1/8" wall thickness. I made the decision that for this first one, I will TIG weld all the joints. I first cut the pieces with my vintage Craftsman horizontal bandsaw. Than spent HOURS on a 4" belt sander squaring the pieces up to length. My goal is to be really precise, +/- 1/32" As a machinist by trade, these seem like wide open tolerances, but lacking the tools of a proper machine shop, getting there has been time consuming, and frustrating. Before I tackle another one of these tables, I will be purchasing an Evolution Rage Saw, as they will cut to an exact, perfectly square, ready to weld length in a few seconds, and with no burr. Having that saw would have saved me EASILY 10 hours off the cut/size/square-up operation. I'm finding that I'm lacking in so many tools that would make this an easy project, but my improvised methods are getting the job done, if not at lightning speed. I've pulled out every c-clamp that I own, along with a good selection of squares, steel rules, etc. I found out right away that my welding table is in desperate need of a flatter top. I priced out a piece of 1/2" steel plate for a new top at $170.00, so it's on the list. The single most important tools that I was fortunate enough to have from my trade school days were a set of heavy angle plates. These plates are super strong and square within .001" so I used them at the base of each square joint to clamp against for tack welding.
I don't have much experience building anything this big, so I'm learning that things MOVE when you tack them!