Plastic X-Idler Plate to replace Wood Parts

Before I take my printer apart to test the plastic X-Motor Mount, it just seemed to make sense to work on the X-Idler plate also, especially since most of the hole patterns are the same. I had some nice suggestions on the design of the X-motor, so thought I would post a photo of the X-Idler model to see if anyone has some ideas for enhancements to this. I just made it as a simple plate, but could add a little reinforcement to it along the top or middle. I followed the same curve design as I used on the X-motor mount design. I will probably add another hole to the upper right as well.
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Does anyone know what that small hole at bottom center of the X-Idler plate is for? Does anyone use that hole for some purpose?

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Originally Posted by PyramidDave

Does anyone know what that small hole at bottom center of the X-Idler plate is for? Does anyone use that hole for some purpose?

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Don't know of anyone who has used it. When I built my i3v-8, I figured it might have originally been for a screw to be used with the original Z-endstop switch, similar to the screw on the Y-bed used with the Y-endstop. It's not in the right position for even that, but that's the best I could come up with.

If you're making it to be paired with the X motor plate, then I'd add the strengthening "welds" you used on the X motor plate, even if they're not needed for strength. Just decorative to make them look similar.

And I'd make it more symmetrical. What's that notch in the bottom right for?

That notch on my version was used to add the Z-endstop adjustable bolt. While I am at this, I should upgrade this to something newer. What type of adjustable Z-endstop are most people using now? I see at least a couple of different ones on thingiverse. Here are the ones that I found. http://www.thingiverse.com/thing:545105 and this one, http://www.thingiverse.com/thing:321810 I have added the extra welds & will take out that little bolt hole & notch.Attachment 6143

Here is the latest image of the X-Idler Plate design.Attachment 6144

You've got that coming along nicely! whats left? Y wooden pieces, a Display holder, and the main Frame and supports?

well done sir... we'll be printing i3V's before you know it :-P I am really hoping the Main frame comes out stronger and lighter than the wooden one :-) I'll be printing everything and revuilding my printer from scratch if you keep this up...

I am working on a one piece LCD holder also and 1st test print of that was close, but the circuit board was a little tight. My reason for doing the LCD panel was to see if I could mount the raspberry PI on its side with power cord pointing down & mounted behind the LCD panel. I will probably get back to some of my other projects after these are finished.

My Z endstop is on the X carriage for ABL.

I changed this to match the similar style change I did for the X-motor taking out the upper & lower right holes. This also leaves the notch in the lower left for those using the notch for the z-endstop micro adjust like I am. This symmetry is carried to the upper right so it does not really look like a notch anymore. The ledge on the outer top & bottom start on that curve about 6.5mm above & below the alum. extrusion so it should miss the X-limit switch for those that have it still on that side like I do. Here is a photo of the current design. I hope to print it today.Attachment 6186

Looking forward to this being released. :)

I have to take my extruder apart to replace the gears before printing this. The plastic was misfeeding & thought it was just the hobbed bolt needed cleaning, but looks like one of the teeth on the small gear is missing. I have about 1000 hours of print time on those gears, so guess it was time. That small gear does not come off easily.

I was able to pry it off after letting some 3 in 1 oil settle into for a few minutes.

I uploaded this to thingiverse today. http://www.thingiverse.com/thing:866648

I finally took my machine apart to replace the X-Motor Plate & X-Ilder plate & related parts. The one problem I did not foresee was that the Z-axis threaded rod connector replacement plastic part did not fit around that outside ledge. Since I could not reprint this before putting the printer back together, I got my dremel out to cut away some plastic to make it fit. I created a new version of this so others will not have to use a dremel on this. http://www.thingiverse.com/thing:795954

One thing on that X-idler plate I might change is to make a slot instead of just a hole for that longer idler bolt to pass thru. That seems like it would add an extra way to loosen or tighten the belt. Does that sound right or am I missing a problem there?

I could not find the plastic part I had printed for the idler pulley, so I used the wooden part on this for now.

I am not sure whether I have the belt at a better tension, but the x-carriage seems quieter running along the aluminum now. I have not printed anything with this new setup yet & probably will not be able to do any test printing until next week, but all the motors seems to work good.
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Here is what I came up with for this slotted version of the idler pulley to move thru for more belt tension. I will not be able to try this until Monday, but looks pretty good design wise to me.
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After thinking about this yesterday, it seems like it needs some support at the thread end of that pulley bolt to keep the belt from pulling it too much at one end. I came up with this idea to replace the wooden circle retainer & be able to adjust the tension with a slotted end of the idler plate. Here is what my 1st design looks like for this. I used a dovetail joint at the outer connection & chamfered a little to make sure it misses the threaded rod. The red parts in the image are for reference on the printer, 5mm threaded rod, bearings & M5x30mm bolt.Attachment 6232Attachment 6233

This seems like it is going to work well. Probably install it tomorrow. Here are some photos of what it looks like. Seems like it will also keep the belt in more alignment with motor.
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Looks Great!

Check it out Dave..
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That looks pretty good. I see you are still using the wooden parts for the Z-axis bolt. You might want to take a look at this part. http://www.thingiverse.com/thing:795954
That is not my design, but I modified someone elses design to my liking. I am just using it for the nut trap & did not use the spring version.I printed

Z-Axis_AntiBackLashMod_2x_NoSpring_1Nut_1_6mmTnutHt_ rev4_repaired.stl from that link. (This prints 2 of them)

It works pretty good & gives me a little more X travel distance. Here is a photo of it on my machine. Here is a photo of it on my machine.Attachment 6271

Thanks, Ill print them out tonight.

Question: how does that piece lock into the x carriage for alignment like the wood one does?

I finally got around to taking my printer apart once again to change over to this new version of the x-idler plate & X-idler pulley with belt tension adjustment. Looks like it is going to work pretty well. I should be able to get the files together to upload to thingiverse tomorrow. I still have the one wooden part for the X-limit switch on that side. Here are some photos of it on the printer.
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I published this new X-idler plate with belt tensioning adjustment today. http://www.thingiverse.com/thing:878023
I am printing my new x-carriage design with this setup now and it is working nicely.