Duender 4040 Extrusion & Aluminium Plate Jig Mod

The 4040 Extrusion X Mount should be printed with 

• ABS or ASA (I suppose most filament should be fine) 
• 40% infill
• 4 walls
• 0.2mm layer height
• 0.4mm extrusion width
• 5 top / bottom layer
• (Aka Standard Voron Settings)

Important Note on the aluminium plates:

The plates are the same on the left and right, not mirrored, the same. Just flip the plate around and the you have the plate for the other side. 

This is done on purpose to reduce the number of different parts to improve part interchangeability and is just a habit of mine when I am designing professionally.

The 4040 Extrusion Y Al Plate should be made with 

• 3mm Aluminium Sheet
• 1/8in sheet is fine or even slightly thicker is fine as the tolerance isnt critical
• 6061 T6 is recommended but most grades are fine
• Use cutting oil to avoid breaking taps, I suppose
• Converting the tapped holes to clearance holes to avoid tapping is an option
• Partial drawing provided for hole sizing
• Closest undersized imperial drill bits are fine for making the holes (1/64in increment sets)

4040 Extrusion Y Plate Drill Guide v2 & Z Plate Drill Guide v2

• Print with PLA or whichever filament is cheap, plentiful, or happens to be loaded
• At least 2 walls
• Scarf seams or random seams help with hole fitment
• Sometimes the holes might be tight so a reamer, endmill, or drill bit helps get the transfer punch sliding smoothly

• The aluminium plate should be scribed / sharpied with the “y-right-plate-guide” / “z-right-plate-guide” clamped to it.
• After scribing, the plate can be rough cut to shape with a hacksaw or similar
• After rough cutting, the plate can be filed to the scribe lines while checking the fit to the drill guides.
• After the plates are a snug fit in the drill guides, a 6mm transfer punch can be used to mark the hole locations
• The plates can be pilot drilled and drilled to final size
• Optional tapping can occur after drilling

4040 Extrusion X Mount (Left & Right)

• Original: “x-mount-l” & “x-mount-r”
• Moved the outer v-slot wheels on the “x-mount” 20mm outwards
• Changed the cutout pattern to a pseudo-isogrid pattern for an immaterial strength and rigidity benefit but mostly because it looks cool
• Sunk the screw heads of the screws that mount to the Al plate so that 25mm screws can be used and be flush on the top and bottom
• Added bridging support on features that didn't print as nicely as they could have
• Added a 6th M3 mounting screw to improve rigidity & clamping pressure

4040 Extrusion Y Al Plate 

• Original: “x-alum-plate-r” & "x-alum-plate-l"
• Same plate for both left and right side
• Moved the outer v-slot wheels on the “x-alum-plate” 20mm outwards
• Uses tapped holes instead of nuts

4040 Extrusion Y Plate Drill Guide v2

• Kinda Original: “y-right-plate-guide”
• Used with the original to accurately position holes (Original is used as a scribe line template)
• Used with a 6mm transfer punch to position holes accurately 

Z Plate Drill Guide v2

• Kinda Original: “z-right-plate-guide”
• Same as the Y Plate Drill Guide, used with a 6mm transfer punch