ShapeOko 2 DW660 Bracket

thingiverse

To secure my DeWalt DW660 spindle on ShapeOko 2, I crafted a custom bracket that fits the spindle's non-round shape well. To enhance stiffness and strength, I designed the bracket to be filled with liquid epoxy (West System's Epoxy) post-printing. The walls are 1.5mm thick and contain internal structure. A limit switch mounting plate is incorporated on the top bracket using McMaster 7779K22. I printed the brackets with Replicator 2 and ReplicatorG software, utilizing 100% infill to fill the walls completely, 0 shells due to a bug in Skeinforge, and a layer height of 0.2mm. STL files were created using SketchUp's Export STL plug-in and Netfabb's STL fixer. A Mouse Ears layer was included for easier part placement on the build plate. After printing, fill the brackets with liquid epoxy to reinforce them. To avoid leaks at the mating face of the brackets, apply epoxy initially to seal the area and then fill up the rest. The brackets are fastened together using M5 x 90 bolts, with hex nuts slipping into a hex-shaped counterbore and secured by retainers. For attachment to ShapeOko 2, M5 x 25 socket head cap screws are used, with washers placed under the head side for added support.