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@Alpharesearch: I agree about the flange on the Z axis gear - it does need to be smaller. It kinda pushes the Z rack out of place. Also, I'm trying to figure out a better way to solve the X set screw so it doesn't hit the table. This may sound funny - but I'm glad that you're having the same problems I'm having. These are the exact same problems I'm looking to solve with the next iteration.