Prusacaster 2025

Disclaimer

This project is still a work in progress and will be updated often. You can find the changelog further below to help you align with any relevant updates.

Background

As MrStolarsky already mentioned;

Now, this is just silly: this is a remix of a remix of a remix of the original design by Mikolas. 

So here we are with an even sillier remix of a remix of a remix of a remix of the original design by Mikolas. 

Finally jumping on the Prusacaster waggon, I ordered the Harley Benton Electric Guitar Kit T-Style from Thomann in the end of 2024. At that time it was on backorder and arrived in February 2025. Being too skeptical to just print it as-is, I double and tripple checked the core module and indeed there seemed to be some deviations. Also, I wanted to have threaded inserts everywhere. So here we go.

The parts here are for the 2025 Thomann kit with 5-hole pickup plate and modelled for threaded inserts (M3x5,7) from CNC Kitchen. 

Thanks go out to FilaFiller for patiently testing and giving feedback!

Needed Parts

General

• 1x Harley Benton Electric Guitar Kit T-Style by Thomann
  • Item No: 115991
  • Variant (?): 202352.0594 (smaller barcode sticker on the front of my box said this)
• 24x M3x8 screws of your liking
  • I'd also keep around at least 7x M3x12 screws just in case
• the orange hexagon parts from the original model (orange_*.stl)
• the output jack holder from the original model

Core 

• 13x M3x5,7 threaded inserts by CNC Kitchen

Knob Holder 

• 9x M3x5,7 threaded inserts by CNC Kitchen

Small Part

• 2x M3x5,7 threaded inserts by CNC Kitchen

Print Settings

• Layer Height: 0.2 or 0,3mm
• Perimeters: 7
• Infill: 25%
• Brim: 5mm, no gap
• Filament: Prusament Galaxy Black PLA
• Temperature:
  • Nozzle: 215°C
  • Bed: 60°C

Note

There is no functional difference in the 0.2mm and 0.3mm version uploaded here, the only difference is the needed print time. To keep print times reasonable, I recommend printing everything in 0.3mm except the pickguard as this might look better in 0.2mm without taking too much more time. If printing time is no concern of yours, you can of course go with 0.2mm for everything or vice versa.

Important

The holes on the bottom left side of the model (in print orientation) - for the top left hole of the guitar pickup plate - as well as the lower hole for the front pickup are out of specification! Normally, there should be at least 1,6mm of wall next to the insert. The smallest distance in this model is 1,3mm (for the pickup plate) and 1,0mm (for the front pickup). I think and hope it works anyway (as it only affects a very small area) and feels okay in the printed part  - but please be aware.

Changelog

2025-10-07

• Updated: Pickguard now hole distance of 71.5mm instead of the 73mm for the front pickup so it aligns better with the part from the Thomann set
• Updated: Adjusted Pickguard STEP, Slices and all project files
• Updated: Removed “Known Issues”

2025-09-14

• Added: Photos of my print to replace the ugly render as default image
• Updated: Added “Known Issues”

2025-06-04

• Added: New Pickguard with more tolerance

2025-05-31

• Updated: Core and 3MF have pre-added supports again

2025-05-30

• Updated: Core with correct hole positions for rightmost wholes on pickup plate

2025-04-20

• Added: Small Part, Pickguard and Knob Holder
• Updated: Core has now only four holes to connect the neck, matching the Thomann kit

2025-04-18

• First version only including the Core

These Prusacaster parts are remixed to take M3 threaded inserts for every screw connection. It's also designed for the 2025 Thomann kit, taking into consideration deviations from the original design.