Openbuilds v-slot X axis for Lulzbot TAZ 4 or 5 printers or the AO-10X ballscrew modification

This project adds a bolt on, no firmware modification required fully supported X axis to the Lulzbot Taz 4 and 5 printers in place of the existing bearing rod.

Build thread is here:
https://forum.lulzbot.com/viewtopic.php?f=16&t=2252

Video:

installation manual is in the works, don't expect it for a few days though.

Edit: the original printed backplate had an error, and was too tall. The new one has been corrected. You will want to print the new one. The CNC version is fine as is.

Edit 2: Uploaded new endcaps and idler tensioner. These parts are compatable with the existing part set. They fix minor geometry issues, add capacity for an X maximum endstop, and move the Idler tensioner bolts out far enough that the tension can be adjusted while the entire rail is mounted on the machine. You do not need to print and install these parts unless you wish to incorporate the additional features to your build. The older parts have been left as a conveniance to anyone wishing to reprint that style.

Edit 3: The instructions PDF is now uploaded! Yay!

Edit 4: A huge thank you to Tom Swanson (http://www.thingiverse.com/Tomscables/about) who assembled and created the An assembly document that includes an exploded assembly view and a much nicer tabulated bill of materials. Open source community helping grow and refine Open Source designs, it's what it's all about. You can view the new document in the uploaded files:
Final_x_axis_Assembly_Diagram_Exploded_view_v1_11_17_2016.pdf

(It is definitely worth taking a look at the picture assembly document as well still)

Edit 5: I have a limited number of the metal backplates available for sale, $25 shipped via USPS to a domestic U.S. address. if you happen to want one, please feel free to send me a message here and we can go over logistics. The printed backplate is adequate for making this work, the metal one is more compact than the printed one, and will fit such things as the cable chain anchors and the bed leveling probe mount.

Print instructions

Category: 3D Printer Parts Summary

This project adds a bolt on, no firmware modification required fully supported X axis to the Lulzbot Taz 4 and 5 printers in place of the existing bearing rod.

Build thread is here:
https://forum.lulzbot.com/viewtopic.php?f=16&t=2252

Video:

installation manual is in the works, don't expect it for a few days though.

Edit: the original printed backplate had an error, and was too tall. The new one has been corrected. You will want to print the new one. The CNC version is fine as is.

Edit 2: Uploaded new endcaps and idler tensioner. These parts are compatable with the existing part set. They fix minor geometry issues, add capacity for an X maximum endstop, and move the Idler tensioner bolts out far enough that the tension can be adjusted while the entire rail is mounted on the machine. You do not need to print and install these parts unless you wish to incorporate the additional features to your build. The older parts have been left as a conveniance to anyone wishing to reprint that style.

Edit 3: The instructions PDF is now uploaded! Yay!

Edit 4: A huge thank you to Tom Swanson (http://www.thingiverse.com/Tomscables/about) who assembled and created the An assembly document that includes an exploded assembly view and a much nicer tabulated bill of materials. Open source community helping grow and refine Open Source designs, it's what it's all about. You can view the new document in the uploaded files:
Final_x_axis_Assembly_Diagram_Exploded_view_v1_11_17_2016.pdf

(It is definitely worth taking a look at the picture assembly document as well still)

Edit 5: I have a limited number of the metal backplates available for sale, $25 shipped via USPS to a domestic U.S. address. if you happen to want one, please feel free to send me a message here and we can go over logistics. The printed backplate is adequate for making this work, the metal one is more compact than the printed one, and will fit such things as the cable chain anchors and the bed leveling probe mount.

Instructions

I'll update these instructions more when i get the X carriage itself finished, but for now you will need some M5 heatset inserts, some of the longer M3 heat set inserts (mcmaster carr is a good source for those) assorted M5 and M3 bolts, M5 T-nuts for the openrail, and the following openrail parts:

1 60mm x 20mm Openbuilds linear extrusion 500mm long extrusion, Manually remove 64mm. http://openbuildspartstore.com/black-v-slot-linear-rail/
4 sets of bearing wheels (http://openbuildspartstore.com/xtreme-solid-v-wheel-kit/ or other sets) ,
2 spacers (6mm probably) http://openbuildspartstore.com/aluminum-spacers/
2 eccentric spacers http://openbuildspartstore.com/eccentric-spacer/
one of their Gantry mounting plates. http://openbuildspartstore.com/v-slot-gantry-plates/
Bolts and nuts (M5, 30mm.)

You will need to cut 64mm off of the openbuild rail. The cut end will be inside the end piece and will not need to be increadibly precise. A standard hacksaw cut will do fine. This will give you a 5mm adjustment gap to be able to move the endcaps in or out as allignment of your printer requires.

Updated part list:

X motor mount
4x 10mm M5
6x M5 11mm Long Heat set inserts (Mcmaster carr )
4x M5 T slot nuts

X motor mount plate
10mm M5 bolts 6x
12mm M3 4x bolts

Left X end
10mm M5 1x
20mm M5 x2
Stock 3 M5 Bolts and washers for Endplate connections

3 M5 T nuts
2 m2 bolts for endstop, 10mm thread

Right X end
10mm M5 1x
20mm M5 x2
Stock 3 M5 Bolts and washers for Endplate connections
3 6.75mm long M5 Heat set inserts
3 M5 T nuts

X idler mount
Stock Lulzbot idler bearings, washers, Nut and large bolt
2 6.75mm long M5 Heat set inserts
2 M5 32mm bolts (the idler adjusters
2 10mm M5 bolts
2 M5 Tslot nuts

X Carriage adaptor plate
4x M3 8mm bolts
11 M3 heat set inserts (the short 3mm-4mm ones)
Stock Lulzbot V notch plastic piece. Stock 4 bolts and washers that hold down that piece (M3 10mm thread plus M3 washers)
The stock Lulzbot carriage hold down bolt and washer (M3 washer M3 bolt 10mm thread)

Backplate
One 35mm long M5 Flat head bolt and Nut (for lower middle Carriage hole )
One 1/4" bolt that fits the larger eccentric holes, also about 35mm long and nut (for top backplate hole)
Spacers and washers to space out middle section of backplate. i ended up using 2x 6mm spacers, a 9mm spacer and a bunch of washers on the top and bottom. this could probably be a printed part. The one at the top is the critical one.
Belt mount posts are made of:
2x 1/8" bolt, 1 inch or so long
4x 1/8" nuts
2x 1/8" threaded plastic spacers wide enough to hold a bolt
2x large-ish washers bigger than the plastic spacers to keep the bolt slipping off the end

Openrails parts:

1 60mm x 20mm Openbuilds linear extrusion 500mm long extrusion, Manually remove 64mm. http://openbuildspartstore.com/black-v-slot-linear-rail/
4 sets of bearing wheels (http://openbuildspartstore.com/xtreme-solid-v-wheel-kit/ or other sets) ,
6 spacers (6mm ) http://openbuildspartstore.com/aluminum-spacers/
2 eccentric spacers also 6mm http://openbuildspartstore.com/eccentric-spacer/
one of their Gantry mounting plates. http://openbuildspartstore.com/v-slot-gantry-plates/
Flat head M5 Bolts and nuts 30mm (standard bolts will not fit, need the flat ones. ).
One 35mm long M5 Flat head bolt and Nut for lower middle Carriage hole
One 1/4" bolt that fits the larger eccentric holes, also about 35mm long and nut
Spacers and washers to space out middle section of backplate. i ended up using 2x 6mm spacers, a 9mm spacer and a bunch of washers on the top and bottom. this could probably be a printed part. The one at the top is the critical one.

The backplate posts are currently made of 2x 1/8" bolts with flat heads, 2 nuts, 2 washers, 2 1/2" long threaded spacers, 2 washers and 2 more nuts. An alternative less mass configuration would also work here.