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Not sure why your rail ended up short, I'm wondering if there were a few rails with incorrect lengths sent out from the factory for the 60mm ones. I do know 505mm long 500mm 40mm wide rails was an issue with some of the Y axis rails. You can as an option loosen the x motor end of the rail and slide it over temporarily to get you operational until your new rail arrives. If you feel like sending me that rail, ill fund the replacement if you feel my measurement is in error. The other concerns I can address. Your idler bearing block should be over much closer to the end of the rail than pictured. The 32mm bolts will engage just fine with a proper length rail, and are indeed 32mm long on both my machines. 35mm should also work though. The printed backplate geometry is not as good as the metal one. If you thin it further, it gets weaker which is also a problem there. It could be improved, and I'll work on that for the next revision. Your zip tie spacing and belt length is too far from the post and leaves too much extra belt. If you shorten and refine that placement you will get full travel. Please see the assembly documentation pictures for ideal spacing. Thanks!