Prusa i3 X-axis Ugrade

thingiverse

Owning this old Folgertech i3 prusa clone for almost 5 years on the original configuration finally decide to upgrade the printer. The parts are designed to work as a form of upgrade for the basic components on the X axis, allowing the installation of 8mm lead screws for the Z axis and replacing the lm8uu bearings with Igus polymer ones. I designed too a new carriage that will allow a double gear extruder like the BondTech BMG to be mounted higher on the axis so the extruder can be matched with a hot end like the E3D V6 without loosing headroom, a BLTouch bracket that can be mounted on the left side of the carriage. The lm8uu are replaced too with Igus ones on this part. The idler is designed on a way that will work as a tension arm at the same time using a screw (I think a #10-32 1" was used for it) and a nut to pull the arm, there is a BLTouch support arm and I'm working on a fan bracket that will lock on the other side to work as parts cooling assembly. The Igus bearings are really particular when it comes to tolerances and while you can dial really good a 3D printer there are many variables (stepper calibrations, tension on belts, temperature and shrinkage values of different filaments) that will affect the tolerances on parts, I found a really easy way to keep them aligned and on position inside the parts, I used a couple of drops of wood glue on the outside part of the bearings just before pushing them on the ends and the carriage and then while the glue was still fresh I assembled and aligned all the parts, in that way the glue bearings will lock the bearings on the correct positions aligned between each other and the rods, if you want to remove later the Igus the only thing that need to be done it's to insert a wood dowel and tap the end breaking the glue and releasing the parts!