The 101.6cm and 101.7cm are the diagonals of the outside frame, right?
Are the lengths of the two X sides and the two Y sides the same? The two X sides of the outside frame are both 800mm?
I don’t understand, but you haven’t wired up the motors, so I wouldn’t be too concerned yet. When you get the motors wired up, use them to draw a big rectangle, and use the measurements from that to decide how to fix it. The motors will move in lockstep (X and X2 move exactly the same distance) so you just have to start the gantry square and it will stay that way.
Make sure you wire them in serial and not parallel.
- Moving a few mm over a 1m tube will not hurt anything. Don’t worry too much about it.
- You can use blocks or hard stops to move the gantry square while you enable the motors. Then you only need 3 drivers.
- You can’t auto square your frame without providing each motor it’s own driver. If it were me, I would ignore the endstops and just wire the double axis in serial. Put some clamps on each pipe so you can snug the gantry up against them when enabling the motors. You can easily get within a few mm with the clamps and over a 1m span, that is good enough for almost any job.