Two steps forward...

Yeah, damn clichés.
Yesterday, as you all saw, the machine was up and running.  However, by the time I left it was once again non-functional.  I'm pretty sure what happend was that the current was turned up to high on the z axis motor, causing it to overheat and eventually burn out.  Usually I keep an eye on motor temp using an infrared thermometer, but it's batteries died.  Thankfully my good friend Calvin had a small stepper I could borrow until I make sure the other motor is dead, or it gets fixed.  I picked it up from him this morning, and that was one problem licked. 
Another issue I had yesterday was that while the machine did work, it was painfully slow; that one part took around 45 minutes to mill out.  This was because the router I was using could only spin at 500 RPMs, which meant I could only make the machine move at six inches per minute.  I can't afford to spend that much time waiting, so I decided to bite the bullet and buy a bigger router.  A wood working supply store near where I live happened to cary exactly what I needed: a replacement motor for a Porter Cable 3 1/4 hp router.  Of course, about an hour after I bought it I get an email from my friend Jeff telling me that he has a mailer from that same store that's advertising a replacement router motor for $30 less than what I paid, plus a $25 gift certificate.  I call the place back, and they told me that if I come back on Saturday (when that sale starts) with just the receipt,  I can get the discount and the gift certificate.  Two problems licked.
I get to the Asylum, rebuild the z gantry using the parts designed to hold the larger router, slap it back on the machine, wire in the new motor, install that, and start testing.
The new motor won't drive the gantry.  Instead it just clutches out.  No worries, the current is probably turned down too low, all I need to do is turn it back up until it has enough power.  After much headache, I realize that the potentiometer on the driver board that is used to adjust the current is ever so slightly broken, so that the board doesn't work unless a slight pressure is applied to the dial.  A small screw and some electrical tape later, and I've MacGuyvered it back to working condition.  Third problem licked.  
Now that it's all working again, I'm calling it a day.  We'll see what happens tomorrow.