Rostock Max v1 Upper Pulley Tension Brackets

thingiverse

I have an early Rostock Max v1 printer with some quirks of its design, including idler pulleys at the top of the delta towers that are notoriously hard to level correctly without belts rubbing against them.\r\n\r\nA neat solution exists on Thingiverse at https://www.thingiverse.com/thing:87463, but I found it was designed for a version of the RMax v1 with different hole locations and sizes in the upper delta towers. Although it improved things, belt rubbing still occurred on idlers and aluminum extrusions of the towers themselves after 6 years of use.\r\n\r\nTo address this issue, I created a bracket that allows for greater belt throw and fine-grained adjustment.\r\n\r\nYou will need to print 12 of these brackets along with other parts including 18 6-32 x 3" bolts, 36 6-32 washers, 15 6-32 hex nuts, 3 6-32 locknuts with teflon inserts, and 9 6-32 aluminum spacer sleeves (6 at 1/4" length and 3 at 1 1/2").\r\n\r\nWashers go on the outside of each bolt, while hex nuts are used on every bolt end except for the non-adjustable top bolt where a locknut is used.\r\n\r\nI printed these brackets at 0.25 layer height with 50% infill in PLA and they turned out rock solid. If you're concerned about deflection of the lower tension-bearing axle bolt in the idler, consider using a size 8 bolt for that; I thought about it but the 6 seemed sufficient, resulting in a little deflection but stable printing nonetheless.