Linear Rail Z Axis for Lulzbot AO-10x and mendelmax printers

thingiverse

This project installs two THK Linear Rails in place of the Z Axis linear rod, upgrading the Z endstop for enhanced precision. Prerequisites include seasoe's LulzBot AO-101 Simple 60MM Height Increase Modification and completed Z-nut springs, Lower X end Clamps, and X Idler from your existing AO-Taz project. You will also need a 40mm longer unused X axis belt or a new one. To proceed, print four Upper Spar mount pieces, two Lower Z motor mounts, a Reinforced and extended X motor End Clamp, and two new backplates (existing ones cannot be reused). Choose between the Micrometer-based Z endstop or another compatible option; if you opt for the former, obtain a micrometer, cut off the upper C arm, and create four aluminum or printed 45-degree angle extrusions. The Upper Spar mount plates attach to the existing upper gantry pieces using existing bolts. The Lower motor mounts replace the original ones, with Z axis motors unplugged during installation. The X motor mount clamp end replaces the old one, necessitating an extended belt. The rail carriages secure to new backplates using flush mount screws and existing hardware. The Z endstop target uses either existing hardware or the micrometer end, which requires drilling two holes for stability. Trim lower angle extrusions by 15mm at a 45-degree angle. Assemble everything, ensuring smooth travel, and begin printing. If binding occurs during Z travel, check backplate thickness and bearing alignment.