Loches Z Axis Upgrade for Prusa i2

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Goals: Boost the Z Axis Build Range and Refine Plastic Parts. Comments: I've extensively modified plastic parts, leaving me wondering if this overhaul is an improvement or a complete reboot of my printer's version. Possible implications extend beyond the MakerGear Prusa, but that's for others to determine. I encountered several issues with the X and Z endstops and had to MacGyver makeshift solutions, which might be worth exploring further through new mount designs. Summary: My initial build area was around 80mm; a print requiring more height prompted me to design modifications for increased build height. Upon inspecting my printer, I identified areas ripe for improvement. The result is a heightened build area of 150mm! Problems and Solutions: Problem 01: The rear-mounted X-axis belt collided with the threaded rod on the triangle frame vertex assembly, creating a clearance issue when raising the nozzle. To fix this, I repositioned the belt to utilize space underneath the X-track rods, which is already occupied by the extruder nozzle. Problem 02: A considerable amount of unused rod space remained on the Z axis due to the motor mount blocking it from extending beyond the top threaded rods. I extended the upper frame vertex piece to elevate the two top rods, and in turn, raised the Z-axis rods. To compensate, I lengthened the lower Z bar clamps, utilizing previously unoccupied rod space. Problem 03: The current extruder mount caused a clearance issue due to the side-mounted motor obstructing the upper frame vertex assembly. I redesigned the extruder mount to address this concern and ensure smoother operation. Problem 04: The new X-carriage endstop needed to clamp onto a single track rod while resting on the other, allowing for free rotation of the rods. This design ensures stable clamping despite the rods' ability to rotate freely. Additionally, the new endstop provides clearance when the Z axis is at its highest point, triggering early enough to prevent the X carriage from colliding with the triangle frame. Problem 05: The Z endstop was now obstructed by the belt, so I aimed it at the motor pulley instead (image provided). This solution works well, but a new mount design can be explored if you're not comfortable with this arrangement. Upgrade Instructions: 1. Replace the original X-ends and X-carriage with the modified parts. 2. Assemble the brass bushings and Z-axis nuts into their respective locations on the new X-ends and X-carriage. 3. Thread the Z-axis threaded rods into the X-ends, leaving about 1/3 of their length exposed from the bottom of each end. 4. Attach the motor mount to the left side of the assembly. 5. Slide and clamp the Z-axis smooth rods through the top motor mount, X-ends, Z endstop, and lower Z bar clamps. 6. Level both X-ends and slide the X-smooth rods through their respective tracks on the X-ends and X-carriage. 7. Attach the X-track bar clamps to the X-track smooth rods, ensuring they're snug but not too tight. 8. Adjust the X-axis belt motor and idler pulleys for optimal clearance. 9. Run your machine and verify that all axes move in the correct direction without binding. If you have any questions or would like to share your thoughts on this upgrade, please don't hesitate to reach out!