Thanks for that, I'll look at ordering a new bit.  More important than the tip though I have to get more rigidity in the frame.  I'm hoping to upgrade to 2060 extrusions on the towers, as well as upgrade the arms + joints.  I found some neat joints, either these http://www.igus.ca/wpck/3752/igubal_WGRM which are a 25* angle but would allow for easy effector replacement, or these http://www.igus.ca/iPro/iPro_02_0090_0000_USen.htm?c=US&l=en which have a 40* angle. 

That's a big delta Sean! Let us know how the routing goes.. I had to put a third arm on mine to deal with the lateral forces.

Check to see if there is a hobby kite store near you.  I picked them up in person from this place http://www.drachenwerkstatt.de/Staebe/fs1_wecfk_cr.php and had a chat with the owner, while he was cutting the rods to my size.  They apparently sell lots of stuff to 3d printer hobbyists as well, I am currently trying to special order a big piece of CF board from them.  My current ones are ID4mm and OD6mm.  I may upgrade in the future to something that has ID6mm and just slip my current rods into, for extra stability.  Important is the ID4mm because you use an M4 grub screw in the Traxxis ends to attach the end to the CF rod.

The rod ends are the standard Traxxis 5347 ones from the original BOM, which I found locally from a hobby shop via ebay.  They were expensive (15€) compared to the amazon.com prices, but work well.

They're panels from those large TVs, like this: http://de.aliexpress.com/item/wholesale-led-dot-matrix-display-module-p5-indoor-rgb-32-32-1-16scan-led-panel-in/1721616932.html?recommendVersion=1

These are driven directly from the raspberry pi's GPIO, so there's a bit of flicker (it looks worse in the video than it really is; ideally you would drive with an FPGA but I'm not there yet)