Aluminum extrusion profile universal GT2 belt tensioner

thingiverse

Long story short, I wanted to make the Dual Z Tevo Tornado modification by Pemic a little more reliable because the printed pulleys were not doing great after a few months of use. I went with 20T/8mm aluminum pulleys that are selling for a dime and dozen but, clearly, I needed another belt tensioner. I also wanted to make the whole setup more precise and universal, so I designed this thing. This belt tensioner allows for the manual adjustment of the belt's tension and can be installed on any >=20mm aluminum extrusion profile/frame. BOM for the default configuration: 1 × 80mm M8 screw 1 × M8 nut 2 × 20mm M4 screws 2 × M4 T-nuts 3 × M4 nuts 1 × GT2 belt idler with a 4mm bore 1 × 30mm M4 screw (can be shorter/longer, depending on how high the idler needs to be) By default, the tensioner has a travel of about 75mm, which is more than plenty for most applications. The travel can be increased/reduced by simply scaling the tensioner across its long axis in your slicer, but take into account that the length mounting and main screws will also need to be multiplied by the scaling factor. If, for example, you need a travel of just ~35 mm's, you can scale the main part to 50% across the long side, but you'll also have to buy two 10mm M4 screws and a 40mm M8 screw.