The pull stud is the only scary part of the mechanism as a whole.
You know I've thought about this a lot. If we only have 1000 lbs of up force then 1001 pounds of downforce is going to start to move the tool into the work. But more than that it's going to let the tool holder wobble which in most cases will be catastrophic to the tool. I can understand the concern about pull studs in regular VMCs that are running 2-5K pounds of force but I just can't see it being a problem at the levels we're working at. Feel free to punch holes in this theory as I'm wondering about all this as well!
I watched your video. Very clever indeed. The opening lid was really a surprise! You should spice that up just for fun. Paint it green and put some big teeth and some crocodile eyes on it. I have to build the spindle and the pneumatics, which are fairly straightforward tasks, and then attack the ATC. I have looked at a lot of arrangements. Mohammad comes to the mountain and vice-versa. Somewhere between ideal, realistic and practical is where It will probably end up.
I was thinking of running a MIDI that went "Bwa Ha Ha Ha" every time it opens and closes! It reminded me of the toy bank coffin that lifted and the hand popped out to grab the coin.
Before I started this maching job I was convinced that mounting my carousel on the end of the table was the best way to go. Keep it simple. Well after watching all of the unnecessary X axis motion with my tool tray I saw the value in flying in the carousel. I think I've settled into the best choice for me which is the ATC is positioned to the left of the spindle and up high enough so my longest tool will be above the spindle nose. This is 8.5". The motion is down 8.5" to bring the fork level with the BT30 groove. Over 8" to engage the fork. Down again 3.5" to clear the pull stud to the spindle. Rotate carousel. Up to engage and then reverse out. Bimba makes a nice 3 position round body cylinder. I used their online configuration tool and it was only $75.00 for a 3/4" cylinder.
Now I just need to find the time to make it!