Just thought I would mention that we got our CNC machine fixed over the weekend. It ended up being not as bad as we thought. There was just a bunch of crud and dust that got crammed into one of the bearing, so we took it apart, cleaned everything, shot some more lube into it, and then wiped down all of the other rods and ball screws.
It's actually pretty amazing that it lasted as long as it did without needing to be cleaned out (this is the first time we've had to do that). We don't realy have any covers over the rods/ball screws, since the gantry has to be able to move back and forth unhindered, there really is no way to make some too, so we'll have to figure out something else to keep the dust etc... off the ball screws in the future (we will probably just have to clean them semi regularly by hand for now until we figure out a more permanent solution).
Anyways, this means I should be able to cut some kits soon. I took the tool paths and started to edit them (fixed a few problems, and made the control panel and bezel area more generic) and am now trying to figure out how to fit 2 kits on each sheet of wood (I use 2 different thicknesses of wood, the sides and control panel are cut from 3/4", so it was really easy to get 4 sides and 2 control panels from one 24" x 48" of wood, but the middle parts are all cut on 1/4" wood, so fitting 2 sets of middle pieces on one 24" x 48" sheet is kind of tricky. I am close, but I have to allow enough room between the pieces to fit my endmill that actually cuts the wood. I would prefer to use my 1/4" endmill, but may have to use the 1/8" so the cuts are smaller...
So, once I finalize those plans, I'll cut one out (2 actually, since I am trying to get 2 kits out of one set of boards), and then I'll probably throw one of them together and document the assembly process, and then start selling them if all goes well. I bought the wood for the tests, just need to finish the tool paths now.