The axel screw extra length has been cut off to correct size, and motor protection and cable support have been securely reattached.
Since the new axel mount position only has an offset distance of about 12.0mm from original axis mount position, I opted to reuse/refactor the original aluminium motor support plaque, by re-drilling new mount and pass through holes.
I also had to make a circular cavity, 3.0mm deep and 34.4 mm in diameter, in order to fit the motor in a secure configuration, that it also had originaly.
The picture shows motor housing on top, attached to aluminium support plaque. And below we have a flexible coupling linking the motor shaft to the ball screw axel, just above the axel support bearing which is attached to aluminium L shapped support.
Now I have to find a viable solution to fix the motor metal protection, that also as a handle, to drag the motor cables back and forth.
After making shure that the rail spacer was as flat as possible, I knew I had another problem to fix. Cutting down 0.6mm of spacer thickness meant that now I didn't have enought spacing for correct alignment. i.e. now it's parallel to Z-axel support bridge, but I need to increase the spacing, to get it on center again.
As can be seen on the first image, after correcting for the missing spacing, now the support is correctly aligned with the z-Axel, since the axel goes through the bearing in perfect alignment.
One solution to correct the missing spacing could be to replace the original clear acrylic part with a thicker one, and fly cut it to size, but I had ruled that out, once I decided to keep the original, and just make it flat by cutting it.
The reasoning for this decision is that this part is large, so replacing it would mean more weight on the Z support structure, due to the extra thickness, and more acrylic scrap leftover. Since I have another clear acrylic spacer, a smaller one, where the Z Rail Support is bolted to the bridge, it's easier, cheaper and faster to replace this part with a thicker one.
Since I didn't have a thicker clear acrylic, hence I used an opaque one I had laying arround. In the second image we can see the rail support sandwhiched between a short opaque acrylic on the left, and a long clear acrylic on the right.
On this image we can also clearly see screw shapped cavities in the clear acrylic, that were used to fix it for fly cutting.
Since I couldn't find a supplier for a 80x80x75x8mm Aluminium L shape, I had to cut an Aluminium bilé that I had laying arround, for making molds. I cut it roughly to the required size, with some extra margin.
I fly cut it to an aproximate thickness size, and chanfered the middle section to give it more strength.
I had to reduce thickeness and chanfer to the correct size, so that the bearing assembly could lay flat, given the required center position. I also drilled 4 fixing holes.
Counter sunk the fixing holes, to provide extra clearance arround bolts heads, to allow enough room for the axel/motor coupling.
Made all required features to lock the bearing assembly in to place. Milled a main passage for the Z-Axel and bored it to size, and later drilled and threaded four M4 screw fixing holes.
Complete L-Support, with all required counter sunk and threaded holes, and counter sunk bearing alignment fixture.
L-Support with bearing assembly bolt into place.