We designed, assembled and evaluated a prototype volume CT scanner (VCT) for the purpose of investigating various calibration methods and cone beam reconstruction algorithms as well as the potential clinical benefits of a high-resolution volume CT scanner. The new VCT is based on SIEMENS Sensation4 CT scanner. To achieve larger volume coverage and higher spatial resolution we replaced the prior 4-slices detector with a flat-panel detector. We also modified the prior x-ray tube to achieve a very small focus size by a smaller emitter and wider axial coverage by a larger anode angle. In addition the high-voltage generator was enhanced to support pulsed operation. Special measurement methods were elaborated and applied to measure the focus size, shape and position as well as the uniformity of the flat field x-ray exposure. The accuracy and stability of gantry rotation speed has been evaluated to decide for the most appropriate exposure trigger. New methods are applied to measure and calibrate the resulted x-ray geometry. One prototype VCT scanner is installed at a pre-clinical site to evaluate the application potential of the new VCT technology. The new volume scanner achieves unprecedented spatial resolution, slice sensitivity and spatial coverage. In a complementary paper we present the image quality, contrast resolution and dose issues associated with this scanner.