After another bit of Maths and some tweaks with the CAD I think I got a bot that should be possible to make. with the bot using 4mm hardox instead of 5mm it can free up weight. Now I have emailed K-cut about cut tolerances and got a response, but I wanted to check with people here.

Should holes be made lightly bigger then I need them to be and add a millimetre or two around the parts to insure they are not cut too small?

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