Prusa i3 Leadscrew, Bearing, ZStop, Belt tension upgrade

thingiverse

This upgrade design for my Reprap Prusa i3 includes X Motor and Idler end replacements that utilize trapezoidal lead screws, improved bearings for smooth rods, and a belt tensioner adjustment. The original design using linear bearings was fragile, so I've made significant changes. I've added holes on the top z shaft mounts for KP08 pillow block ball bearings to further steady the trapezoidal lead screws. However, I don't have them installed yet as my motors won't drive the additional load they impose. Thanks to Thingiverse users for their contributions: the X adjust inspiration came from http://www.thingiverse.com/thing:111903 and the Z end stop idea from http://www.thingiverse.com/thing:542892, which I've incorporated into this upgrade. Take a look at my X Stop design on Thingiverse: http://www.thingiverse.com/thing:1798572. Since then, I've updated the Z Shaft Mount STL files due to an error in one of them, and added different length Z Stop arms that mount to the X Axis assembly to accommodate various extruders. Pick the version that works best for you - the short version should always work but will require a longer screw. The medium version is the original length, while the long version is included, though I'm not sure if it's of any use. I've added the SketchUp file so others can improve upon this design. Unfortunately, I've put my i3 clone on hold for now as I'm working with another printer when I have time. Print Settings: Printer Brand: RepRap Printer: Prusa i3 Rafts: No Supports: No Resolution: 0.2 Infill: 20% Notes: Support is needed for the Z Stop arm, X Motor end, and left side Z motor mount. I may manually add support material to these parts in the model files as Slic3r tends to add support even where it's not needed. Custom Section: Required hardware includes T8x2 trapezoidal lead screws (200 mm, single start), 5mm to 8mm NEMA 17 couplers, KP08 Pillow Block bearings (optional), and SCS8UU Linear Motion Ball Bearing. Additionally, you'll need misc. hardware, such as longer screws for the left X motor and SC8 bearing hardware. A spare spring on the Z stop screw helps prevent it from changing position due to vibration.