I added a set of standard rails to me xxl and built a custom t slot structural frame for it. I have a video showing the process for anyone interested. https://youtu.be/6QhmluXsYPo
Cool project, Chris! I enjoy your videos.
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For a lot of projects this is perfect. Sometimes you just need a lot of capacity and not necessarily more rigidity or precision etc.
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Hey @ChrisPowell,
I dig the FrankenPoko name 
One question: when you started this, did you consider making the machine twice as wide rather than twice as deep, since tiling could provide virtually unlimited Y ?
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This was pretty much the plan from the beginning. I didn’t like the idea of not being able to support the x rail like I could when doing the y rails. It would be a different story if you could get longer pieces of extrusion.
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Do we know if this will function for the rails of an S4…? Yes Chris I’m also talking to you on YouTube but figured this might be a better place for the discussion sorry buddy lol.
I’m aware the way the waste board is wouldn’t be ideal but that’s small potato for what I have in mind. I just need a longer Y axis so if this is applicable to the S4 I’m in love 
I think you’d be hard pressed to get your hands on a second set of S4 rails https://community.carbide3d.com/t/expansion-packs-shapeoko-4/33254
Sounds like carbide could just sell me a set of rails…? Lol
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