X motor mount and Z rods fix (P802Q upgrade)

thingiverse

## What this? My attempt to fix some issues with Zonestar P802Q printer (Prusa i3 clone). Includes X motor, cooling fan mount and more to fix problems with XY axis parts. Designed to increase rigidity and fix a few bugs in the original design. I couldn't find an "all in one" solution for all my problems so I decided to develop a design from scratch that fits my needs. I tried to keep compatibility with the original geometry of P802, but some components were changed (e.g. optical endstop sensors). Therefore it's a good idea to read the rest of the description if you're going to print this project or part of it. The project was developed in a parametric CAD system (FreeCAD) so resizing and refining for your needs shouldn't be a problem. ## General remarks The project was designed with minimal bridges and supports to simplify printing even on low-cost machines. This is why the X motor mount was split into several parts which should be glued after printing (acetone may be a good choice if using ABS filament). It also facilitates the change of individual elements (for example, no need to rework the whole motor mount to change the Z endstop part). All elements were printed with 25% filling and extra perimeters (6 perimeters gave me a pretty satisfied result). And yes, it makes sense to spend some time on parts post-processing (e.g. sanding and treatment with acetone) because these elements are always in sight. ## X Motor Mounts Goals: * Increasing the rigidity of the motor X mounting * Pulling up the X belt level to avoid belt friction and carriage mount * Adjusting the shape of the tunnel for the X belt (to simplify printing) * Reworking the Z level flag to use an optical sensor * Reworking the X endstop mount to move it from the carriage and use an optical sensor instead of a microswitch. * Organizing cables based on https://www.thingiverse.com/thing:193948 chain * Changing the tensioner roller (right mount part) to utilize two F623ZZ bearings The X motor mount block (left side part) consists of: * Motor mount (XMountL.stl) * Flag holder for Z endstop (ZEndstopHolder.stl) * Cables holder (XCablesHolder.stl, XCablesHolderCup.stl and XCablesSupport.stl + https://www.thingiverse.com/thing:193948 chain) * X endstop sensor holder (X endstop sensor moved from carriage to the X motor mount) The right mount was changed to adjust the tensioner roller. For me two F623ZZ bearings with restrictive rims is a better match than the original construction. Also it should be possible to use an idler pulley for GT2 belt and 3 mm bore. And I abandoned the idea of an adjustable tensioner in favor of a simple and reliable design. ## Cooling print area Goals: * Optimizing the airflow path and using the origin radial fan * Cables organizing based on https://www.thingiverse.com/thing:193948 chain (part 2) I am pretty sure that it is very difficult to design a worse airflow path than in the original cooler holder. The fan was shifted to the right to get rid of the Z bend in the channel. And the duct cross section at the outlet was reduced to increase the air flow. It should work fine for default MK8 hotend but most likely should be adjusted for Volcano version (this version is slightly higher and therefore the air flow should be a little lower). Mounting hardware and cooler are the same as for the original version. ## Z Rods mounts In the original P802Q version, Z rods were mounted only in one point (only top end for smooth rods and motor mount for threaded rod). My main goals were to fix both ends of rods and simplify the installation procedure. ZRodMountButtom.stl should be used to fix smooth rods at the bottom point. You may need bolts slightly longer than the original ones. ZRodMountTop.stl was designed to use cheap 688 bearings (8x16x5mm). Can be easily adjusted to use another bearing or bronze bushing. And yes, all rods must be in line therefore, the setting can be facilitated using a long ruler or any other object with a straight side.