Prusa XL modified Left and Right Y-Carriage for Toothed Idlers Pulleys with 10mm width (for new O-Rings / Washers)

Hello XL makers!

This is a Remix for the Prusa XL Y-Carriage for toothed Idler Pulleys with a width of 10mm.

I have written a detailed article about this, which deals with Gates' manufacturer recommendations:
https://investegate.de/prusa-xl-toothed-vs-smooth-idlers-on-2gt-belts/

In addition, there have been new spacer O-rings for the Prusa XL since the middle of 2024. Just a few weeks later, Prusa changed this again. They now use black nylon washers.

This remix is only compatible with the new O-rings or the new Washers.

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Print Settings:

• 0.4 or 0.6 nozzle

• 5-7 perimeters

• PC-CF or PA-CF

• 0.25mm layer high 

• min. 30% Infill 

The layer height should really be 0.25mm. I had problems when I printed it at 0.2mm, because the pulleys had too much play.

I offer another special option here. I changed the parts slightly regarding the hole for the pulley axles. I made it smaller because I didn't like how loosely it was attached. This is because the holes for it are 3.25mm by default. The rod is about 2.9mm thick. I made the holes smaller to 2.8mm and then drilled them out with a 2.9mm drill bit. The rods are now nice and tight. So you will need a 2.90mm drill for this ;)

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There are 2 pulleys on the XY carriage where the belt touches the pulley with the toothed side. To prevent the belt from deforming, toothed pulleys should be used here.

I have written a detailed article about this, which deals with Gates' manufacturer recommendations:
https://investegate.de/prusa-xl-toothed-vs-smooth-idlers-on-2gt-belts/

They must have the following designation:

GT2, 20T, 6mm belt, 3mm bore, toothed, 10mm width.

The pulleys can be found here, for example:

https://meltbro.de/gt2-umlenkrolle-pulleye-20-zaehne-3mm-m3-bohrung-fuer-6mm-zahnriemen-2gt.html

https://www.filastruder.com/products/gates-2gt-idler?_pos=1&_sid=1d42bf29e&_ss=r&variant=32673878442055

There are also many suppliers of these pulleys on Amazon, eBay or Aliexpress. However, you usually only get cheap no-name pulleys there. That's why I remixed this too.

I also recommend this mod: https://www.printables.com/model/1272492-prusa-xl-modified-corexy-parts-for-new-o-rings-or

Or if you want to change all Pulleys to 10mm LDO ones: https://www.printables.com/model/1135912-prusa-xl-modified-corexy-parts-for-new-o-rings-or

For toothed idler pulley with 10mm width for the new O-rings or the new Washers.