XR SuperFlux Axle Blocks

It seems nobody has made SuperFlux Axle Blocks with a handle so here we go.

I put the handle on the left side (motor wire side) so it doesn't interfere with the valve stem. I designed a bottom plate with cooling fins to cover the motor wire slot. When installed, it matches the right side block in appearance.

The side without the motor wire (the right side) is solid with no slot for a motor wire.

This is for XR rails only. My SuperFlux is a V3, so I have no idea if it works with prior versions. The handle is designed to be 3D printed, while the rest of the parts are designed to be machined out of aluminum.

Machining Instructions

• Send to your favorite CNC shop. I chose PCBWay.
• Specify your materials. I chose the following:
  • Right Side: 7075 Aluminum
  • Left Side: 7075 Aluminum
  • Left Side Bottom: 6061 Aluminum
  • Handle: 3D Printed MJF HP-PA-12
• Send the included technical drawings for thread tapping and heat set inserts. Each part has:
  • Right Side: Tapped Threads
  • Left Side: Tapped Threads
  • Left Side Bottom: None
  • Handle: Heat Set Inserts
• Also send the included technical drawings for important tolerances. Tightest tolerance per part are:
  • Right Side: +-0.05
  • Left Side: +-0.05
  • Left Side Bottom: +-0.06
  • Handle: N/A

Additional Parts Needed

• (2) 5mm x 10mm x 4mm Bearings
• (1) 5mm x 55mm Rod
• (2) Pair 3/8" x 1/8" Round Neodymium w/ Countersunk #4 Screw Hole (1 North face, 1 South face)
• (2) 1/4"-20x1/4" Set Screws (uses 1/8" hex like most XR fasteners)
• (4) M3-0.50x8mm Flat Head Screws (uses 2mm hex like VOW box fasteners and maybe others)
• (4) M3-0.50x10mm Flat Head Screws (uses 2mm hex like VOW box fasteners and maybe others)

If you are 3D printing the Handle yourself, or the shop you are using doesn't offer heat set inserts, you will also need the following:

• (2) 1/4"-20x6.4mm Heat Set Inserts
• (2) M3-0.5x5.7mm Heat Set Inserts

Handle Assembly Instructions

1. Use the M3-0.50x8mm flat head screws to install the magnets into the Left Side and Handle, ensuring they attract each other.
2. Press the bearings into the Left Side.
3. Place the Handle onto the Left Side, slide the rod through, and secure it with the set screws.
4. Install the assembly onto the Superflux Axle, routing the motor wire into the channel.
5. Use the M3-0.50x10mm flat head screws to attach the Left Side Bottom.