Wow, no updates in over a year, that sucks. Sorry!
After being MIA from HaD for most of this year, I would like to announce "no, this project is not dead".
Long story short: life and other projects intervened. One project in particular paid quite handsomely, and the gig lasted for several months, but it took 100% of my time and energy.
Anyway, here's the deal on the 6040 CNC project....
I recently got a mini-mill, a mini-lathe, metal bandsaw, and tooling, so I now have in-house manual machining capability. I definitely intend to continue with the 6040 CNC rebuild, and the new gear might be helpful, but setting up and learning the machines is highest priority right now, and there are many other projects waiting for attention, so the next update on this project could still be a ways off.
"Never, never, never give up." - Winston Churchill
"It does not matter how slowly you go, as long as you do not stop." - Confucius