
Adjustable Z Endstop for Prusa i3
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Summary One of my first printer modifications was adding an adjustable Z endstop (http://www.thingiverse.com/thing:1253186 and http://www.thingiverse.com/thing:149882) to my Hesine M505 Prusa i3. The endstop worked well until I upgraded my X axis (http://www.thingiverse.com/thing:1103976). With the new X motor mount, the Z plunger no longer aligned with the endstop switch. I created a design based on the original endstop mount that would align with the new X motor mount. I then decided to redesign the offset adjustment plunger mount for better switch contact and screw tensioning. This thing is the result. The Z endstop and offset mounts are relatively simple, just install as per the attached images. The plunger might require some explanation since some components are internal and not visible in the images. I believe the adjustment screw and associated nuts are #6, sourced according to the original design. The screw used is about 3 inches long. To assemble the offset mount, attach a nut to the adjustment screw so that approximately 5mm of thread extends past the nut. Place another nut at the bottom of the mount. Put a small section (about 8mm) of 3/8" compression spring over the end of the screw, resting on the nut. Insert this assembly into the top of the mount, compressing the spring and screwing it into the nut on the bottom of the mount. For the plunger (the part that contacts the switch), install a nut into the recessed area and then glue the bottom piece in place, trapping the nut inside the assembly. Then attach another nut to the end of the adjustment screw with about 4mm of thread extending past the nut. Screw the plunger assembly onto the end of the screw and tighten it using the nut. You will need to screw the adjustment screw in as far as possible to access the mount holes for attaching the offset assembly to the X axis motor mount.
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