Apologies for the delayed reply.
In response to James' questions:
The magnetic strips are easily cut to length. I think I just used tin snips. The aluminium extrusions obviously need to be cut with a hacksaw.
The mounting for the display is fixed to a thick aluminium plate behind the pressed-steel cover. This reinforces the mounting substantially.
Regarding my thinking behind how I mounted the scales and readers, it was all about future-proofing. Specifically, my objectives were:
1) To leave each of the three scales as long as possible to potentially mount them to a different machine in the future
2) To ensure the ends of the table are completely clear of mounting brackets, etc., to allow a power feed or even CNC motors to be mounted in the future.
I think this answers your questions so far.
I am still not too happy with my Z-axis readings. I think this is due to the 'spring' in the machine between the movement of the leadscrew nut and the head movement. I haven't investigated whether this is the gib adjustment, which may be a little tight, or whether it is fundamentally the fact that the reader is some way from the head. The travel of the feedscrew nut, to which the reader is fixed, doesn't perfectly follow the height (Z-position) of the head. The movement also seems to be too juddery to rely on for accurate height settings, hence why I use the quill for accurate height settings.
Jason: I'd be very interested in your thoughts on this. Specifically, would you expect to be able to set the head height just as accurately as the quill? Also, do you have any hints on how best to set the head gib so that it's not too tight or too loose? (Perhaps this is one for Ketan?)
Cheers,
Mike