Folgertech FT-5 X Idler upgrade

thingiverse

Please note: For those with the newer version of the FT-5 with the new style idlers, I have uploaded a revised X idler lower body to accommodate the difference in hole sizes of the factory X idler brackets. Essentially the revision is the same less the locator pin as currently equipped. It is listed as XMAINBODYLATE. Thanks to the folks that let me know of the design differences. This is a more robust design of the Folgertech FT-5 X idler assembly using more commonly acquired 608 bearings also widely used as skateboard bearings designed to be a drop in modular assembly for the originally equipped components. Feedback positive or negative is always welcomed and encouraged "of course if tastefully spoken" as that is how we all learn. If this works for you please show it off by posting a make of it as it is what keeps inspired to do more. If for some reason it doesn't, please let me know and I'll do what I need to to make it work. Thanks to John Folger for the awesome machine he has made so affordable everyone should own one! Print Settings Printer: Folgertech FT-5 Rafts: No Supports: Yes Resolution: I used .2 layer height Infill: I used 20% but recommend 50% and up. Notes: Parts are designed to have the halves mating flanges as flat as possible so orient the lower half upside down so it is touching the bed. Post-Printing Assembly instructions and bill of materials to follow Parts list. 1 608 bearing and 1 F608 bearing preferred however 2 standard 608's can be used with a washer between top of pulley and upper bearing. 1 m8 smooth rod 33mm long chamfer each end for idler axle. 1 GT2 20 tooth X 8mm pulley with set screws. Link for these https://www.amazon.com/gp/aw/d/B019GIJ296/ref=mp_s_a_1_1?ie=UTF8&qid=1496123258&sr=8-1&pi=AC_SX236_SY340_FMwebp_QL65&keywords=gt2%2B20t%2B8mm%2Bpulley&dpPl=1&dpID=51s-XR%2B4CcL&ref=plSrch&th=1&psc=1 1 m5 x 10 hex head cap screw and companion t-nut. May have as spares from kit. 4 m3 x 16 hex head cap screws 2 existing m3 drop in t nuts. Perform post print clean-up of support. Press upper bearing into top cap. Press lower bearing down through idler body and seat in base. Loosen X motor mount bolts to release belt. remove existing X idler top melamine piece and existing idler pulley. slide belt through opening of new X tensioner body. Install pin into bottom bearing through the belt opening. Slide pulley down over pin through belt orienting the pulley retainer end to the top. Prepare top bearing plate by putting 2 m3 screws through the holes in the outside of the plate threading them in just to the mating edge. Install top bearing onto smooth rod and slide top plate down to mate the main body. Tighten the outer screws down just finger tight. put 2 remaining m3 screws down through both parts and start the drop in t-nuts on the screws. install new X idler assembly down over the extrusion centering the locator pin in the lower melamine plate and dropping the t-nuts into the extrusion. tighten down the mounting screws then final tighten the outer m3 screws making sure everything is aligned and flat to each other. Slide the m5 t-nut into the end of the extrusion on the front side lining it up with the hole in the X idler body and install and tighten the m5 bolt. Seat belt in idler pulley and adjust belt tension and lock down motor bolts. While holding X idler pin down in place, move the shuttle back and forth to align the pulley with belt travel then stop when a set screw is visible in screw portal. tighten set screw then move shuttle enough to expose the second set screw in the portal and tighten down. Done! On to the Y idlers. How I Designed This Designed to be a drop in replacement for the orignal x idler.