A few design changes

[Chuckles182]

Hi I'm super excited about this project! While waiting for parts to come in from AliExpress I decided to change a few models to use parts from my old Ender 3. One thing led to another and I've made quite a few changes. I am still waiting on my control board and have never used RepRap Firmware before, so I have no idea how my changes will work.

Screen shot of printer in Fusion

Base Frame Support
Added a little more support to help lock things in. I also have the vertical 20x40 extrusion on top of the horizontal 20x40 extrusion so I could use Ender 3 threaded rod and extrusions.

X Axis motor and pulley/idler assembly
I changed the way the idlers and motors are mounted, now a single M3x40 holds the F695 2rs idlers and the stepper motors. I think it makes assembly a little easier. The angled piece is one solid unit.

X B Cable Relief
I need to add slots for zip ties to go through, and cables...

X B Motor mounts
I changed quite a few things with these. I adapted the threaded rod screw to fit the one from an Ender 3. I Added atachment points on the outside to use heat set inserts instead of M3x40 as they're harder to source. This let me make the walls a little thinner for heat management and print times. I added a honeycomb pattern for airflow and cause it looks cool. On the rear cover, there is a spot for a cable relief mount, the right hole accepts a M3x40 for additional support.

Z Axis Motor Mount
I changed this to be able to use the threaded rod and coupler from an Ender 3.

Z Stop
I made and printed two of these, originally the top one butted up against the Z motor mount to use as a reference point. They help assure that both linear rails are parallel with each other.

X B Belt Tensioner
I remixed a Ender 3 X axis tensioner design from Printables. This uses the Ender 3 idlers so I think belt clearance shouldn't be an issue.
https://www.printables.com/model/1137828-4-axis-x-axis-tensioner

Wow! That was a lot more than I had anticipated! I'm still modifying the B Axis and hot end mount so it can use a Phateaus hot end I have from previous build and an orbiter v2 extruder set up to use a bowden tube. I'm still debating on what I want to use as a print bed. I found some on Amazon, combined with a slip ring I think a heated print bed would be possible. If there's interest I can work on uploading .3mf and .STEP, but I wanted to wait till I was done with all my plans.
Oh yeah and I have to actually wire it up and get it moving! That is what I am most concerned about, as I am much stronger in modeling than I am in software/firmware.
Let me know what you think! Thanks!

[TheOnlyMann]

this was made from all Ender 3 V3? thats awesome.

[jyjblrd]

That's incredible, would happily accept some contributions to this repository when you're happy with your design. Feel free to post on here if you need help with the wiring / configuration stuff

[xobes]

This is looking nice. I can't wait to swap out some parts for your designs. :-)

[TheOnlyMann]

i dont remember the MGN12 attachment point being slightly raised, was that a new addition?

[Chuckles182]

It is a new addition, because I used the lead screw coupler from an Ender 3 it pushed the linear screw a few mm away from the vertical Z axis 20x40 extrusion. I had to add a few mm to the MGN12 attachment to compensate. It moves the print head a few mm off center, so I will have to move the print bed out to compensate.

[TheOnlyMann]

on a unrelated note, @Chuckles182 does yoru design changes from idlers to bearings also changed some of the pullies? or are they still 16t pulleys. cause i thought the bearings you used are usually replacements for 20t idlers, not 16t

[Chuckles182]

They are 20t pulleys.

[TheOnlyMann]

interesting, been making up the BOM list so wanted to know

[ehegenberger]

Looking forward to putting on these extra parts!
I had my first order for my new 3D print farm (OK, more like a herb garden at this point) this week, so I've been busy with that, but my last linear rail finally arrived, can hardly wait to see it in action!