Adjustable height conduit leg system

thingiverse

This design enables mounting 3/4" conduit legs securely to the ends of a FreeMo module for model trains. After successfully printing this object, I have installed them on my modules for further durability testing. The mounting slots are specifically sized for #8 sheet metal screws. The bosses are designed to be drilled and tapped 10-24 for a thumbscrew to retain the leg while moving the module. All parts were created with the intention of printing without support. The upper part of the leg is 3/4" EMT conduit, measuring 30 inches long. The lower part of the leg is 1/2" EMT conduit, measuring 20 inches long. This setup will allow for a leg that can be adjusted from about 40" railhead height for NTrak to the 50" FreeMo height. The "Leg End" parts should be printed with high infill for added strength, as they are press fit (hammer in) to the inside of the 1/2" conduit. To accommodate a 1/4" or 5/16" x 3" long carriage bolt, you will need to use a tap on the appropriate sized part, either Leg End_250 for a 1/4" or Leg End_312 for a 5/16". The "Leg foot" parts are designed to fit 1/4" or 5/16" carriage bolts and should be printed in a flexible material to protect floors from bare bolt heads. The "Leg foot cap" should be printed in a rigid material, engaging the square feature of the carriage bolt for fine height adjustment. You will also need some 1/4" hardware for the pinch clamp on the "Leg pinch joint" part. This is another component that should be printed with high infill for maximum strength. Be cautious when tightening the pinch bolt - it doesn't take much force to lock the leg into position! 04-22-2017 All parts were redrawn in Fusion 360, making revisions significantly easier than using TinkerCAD. Revisions: Leg pocket: A "vee" groove was added opposite the thumbscrew hole for even better alignment of the leg when clamped. Leg end-312x500 & Leg stabiliz-500: Part of the flange was removed to allow changing print orientation, improving strength and eliminating "popping off" the flange when driving it into the conduit. Leg end-312x750: This part allows for fixed-length legs using only 3/4" EMT conduit. Leg pinch joint: The size and depth of the spot face were reduced to increase strength in the pinch bolt "ear", and 1/4-20 panhead screws are recommended instead of bolts for a proper fit. 11-04-2017 A pocket design was added for 1/2" conduit legs - "half inch.stl". Print Settings: Printer Brand: RepRap Printer: Original Prusa i3 MK2 Rafts: No Supports: No Resolution: 250 micron layer height Infill: 50% Notes: Thus far, parts printed in PLA have proven sturdy enough. Further testing is needed for heat resistance. I may attempt annealing some parts before tapping to see if they work any better.