Zonestar Z5 Mods

thingiverse

My Zonestar Z5MR2 came without a mount for the X endstop, which caused several issues with the printer's accuracy and reliability. The cable for the Z endstop didn't match the switch that was mounted to the frame, leading to further complications. Additionally, the Y endstop allowed the bed to home too far back, limiting the usable area of the bed. To fix these problems, I created a new mount for the X endstop and rewired the Z endstop to match the factory switch's connector. The new mount attaches to the inside vee rail and allows for more adjustment options. I also added a hole for ziptie attachment to provide strain relief for the cable. The X endstop mount is designed to be compatible with all factory hardware, and it should be positioned so that the nozzle is over the bed when sent a G0 X0 command. My printer's homing position was around -28mm. To further improve the printer's performance, I replaced one of the spacers for the wheels under the Y carriage with a new endstop mount that contacts the microswitch button. This change allows the Y carriage to home at the front edge of the bed instead of 20mm in front of it. Later updates include adding a mount to tilt extruder motors 45 degrees forward, reducing bowing and improving filament path alignment. I also modified the extruder drive to use a RepRap Champion MK8 hobbed gear, which requires some additional bearings and re-tuning of extrusion steps.