Loches Z Axis Upgrade for MakerGear Prusa Mendel

thingiverse

Update May 20, 2012: Elevated X-Carriage Endstop holder for clearance with triangle frame added. May 13, 2012 Update: New X-Carriage version introduced requiring no support; user must cut excess material after printing. Note: Not yet printed, so functionality unconfirmed. May 12, 2012 Update: Pink Panther Woman printed at full size demonstrated in video http://youtu.be/c93jLzPYmBQ. Goals: Increase Z-axis build range, modify plastic parts only, reuse Vitamins. Challenges and Solutions: 1. X axis belt collided with threaded rod on triangle frame vertex assembly, causing clearance issue during height adjustment. Solution: Relocated belt mount under X track rods. 2. Rod space on Z-axis went unused due to motor mount blocking beyond two threaded rods on top printer. Solution: Extended upper frame vertex piece to raise top threaded rods and Z axis rods. 3. Existing extruder mount caused clearance issue with upper frame vertex assembly. Solution: Modified extruder mount design for rear-protruding motor. 4. Tightening X track rods caused carriage binding. Solution: Replaced tension screws with clamps on rods, providing stability without binding. Materials and Steps: 1\. Remove and disassemble original Z-axis parts. 2\. Install new upper frame vertex pieces, Z motor mount plates, lower Z bar clamps, X-ends, X-carriage, X-Endstop holder, and brass bushings. 3\. Assemble Z axis threaded rods, smooth rods, and clamp in place with bearings and motor couplings. 4\. Level X-ends and slide Z axis smooth rods through lower Z bar clamps, X-ends, and X-carriage. Clamp X track rods using X-track bar clamps and nuts/bolts. 5\. Attach belt motor, idler pullies, and new X-carriage endstop holder. 6\. Adjust Z endstop aim if necessary. 7\. Test machine movement, double check calibrations, and enjoy increased build range!