Hi All,
I really liked the original makerslide router idea and was a bit disappointed to see that this thread died out. I decided to build my router using misumi 4080 extrusion, cold rolled flat bar and routerparts carriage for linear motion.
I designed and printed all the plastic parts (motor mounts, couplers, idlers...) on my reprap.
For electronics I am using sanguinololu board, which is designed for 3d printers, but it works well on this setup with 24V power supply.
I am using Marlin firmware (also designed for 3d printers) that I hacked to remove things like temperature control and change E axis for extruder into another X axis since I am using two motors for X and they are both hooked to a separate driver.
Here are few pictures and a video of it cutting some mdf. Machine can move much faster then in that video, but I need to do some testing with rotozip to see how much abuse it can take before something breaks. It is still very much work in progress. Comments are welcome
http://www.youtube.com/watch?v=xejmM8sq3jg