Leadscrew Upgrade X Ends for Wilson / Prusa i3

thingiverse

These new X-ends integrate changes from the Wilson II into the Wilson TS X-end, adjusting geometry to match the Wilson TS and resized for 8mm linear rods and an 8mm leadscrew with a brass nut (I purchased mine from Folgertech, the affordable THSL-8; it seems that all use the same nut). These should fit standard Prusa i3 geometry since the Wilson TS uses the same geometry (if I am incorrect, please leave a comment so that I can update the title and avoid misleading anyone). This uses tensioner and x-carriage from the Wilson TS. In addition to supporting leadscrews, I also integrated new strain reliefs on the motor end, and ridges for preventing tensioner pitching/cutting out to add more travel to the idler end. This does lose about 3mm of travel on the motor side, but adds more on the idler end. The end stop switch can likely be moved inward another 3mm to avoid losing any travel on the motor end (change x-end-motor.scad:endstop_sw_offs_adjust), but I realized that after printing and left the position alone in the STLs since I know the current version works. The OpenSCAD source code is available at https://git.hcoop.net/?p=clinton/wilson.git;a=summary and is licensed under the GPLv3+. These changes could possibly be integrated back into upstream Prusa i3 as well. I had to print http://www.thingiverse.com/thing:1347181 because my leadscrews are taller than top rod holders, and I had z-wobble issues (my M5 rods had similar issues before cutting them below the top rod holders; however, I didn't want to cut the leadscrews since I may build a taller printer later). My frame is slightly too tall for its own good (470mm linear rods), so there might not be any problem with the leadscrews poking out of the top rod holders on a normal height Wilson TS. Note: although my layer quality is better, my printer is slower with this because leadscrews are stiffer and when they vibrate, they seem to make x-axis shake back and forth more (= ringing become excessive at 45mm/s instead of 60mm/s). I also extended my x- and z-axes by 100mm and 8mm smooth rods don't seem stiff enough at these lengths anyway (450mm z, 470mm x) so YMMV if you didn't make your Wilson way too large. I am working on a 10mm variant of these that will be combined with Prusa i3 z-axis parts with a new extrusion_frame option. Print Settings Printer Brand: RepRap Printer: Wilson 1.0 Stretch Rafts: No Supports: No Resolution: 0.2mm Infill: 50 Post-Printing Follow the normal Wilson TS instructions for assembling the parts. You will need 3x M3 lock nuts and 14mm M3 bolts to secure the brass nut. I added a nut trap for the third nut that goes into the body of the idler. You might be able to just use two bolts. If you have a different hole spacing pattern, just modify x-end.scad:nut_trap() to place mounting holes where you need them.