Ender 5 S1 Linear Rails Upgrade

My own take on the designs that came before me. MANY thanks to their hard work and generosity in providing the models.

My main goal was to make my parts easier to print and fit. I've included parts diagrams and photos of the three main sections to show them assembled: Head, Y-Axis Left, Y-Axis Right

The head includes a Rear Bracket, to which you attach the CR-Touch and Cooling Duct from below and the board sits in front.  The Front Bracket mounts on top of the X-Axis carriage and holds the belt, hot end and extruder. The Rear Bracket attaches to the back of this. 

The X-Axis Left includes a Bottom, Top (Head) and Top (Cap) and a Belt Tension. The Bottom mounts to the Y-Axis Left carriage and holds the belt. If you assemble the X-Axis Belt Tensioner and pull to the Left of the X-Axis gantry, this should sit down onto the Left Top (Head). The Top (Head) screws down to the Bottom from above. You can now screw down the Left Top (Cap) and secure the Tension block.

The X-Axis Right includes a Bottom and Top. The Bottom mounts to the Y-Axis Right carriage and holds the belt. The Top sits on top of the Bottom and screws down to the bottom from above. If you fit the X-Axis Stepper gear into the belt you can sit the motor at an angle to access those screws. Now rotate the motor into the correct position and screw down onto the Head.

The X-Axis limit switch mounts vertically and screws to the back of the X-Axis Right Head with two screws. 

The Y-Axis limit switch remains as per the original Hoon design, so please visit his Linear Rails solution or use the copy of it I've included.

The bed has to be lifted slightly to reach the new hotend position, as it all sits slightly higher on the linear rails. Hoon also provides spacers, or fit some spacers of your own to about 6mm height between the platform and the bed on the adjustment screws. I've also included Hoon's spacers here.

You will need to edit the printer.cfg (Klipper) to define the new CR-Touch offsets. The cr-touch now sits with zero x-offset to the nozzle as shown in the linked video:

I've included a link to a short video with a look at my design assembled and working.

The weight reduction from the v-slot and wheels is quite noticeable. I've been able to increase speed and acceleration without the belts jumping or motors locking. Maximum speed is about 550mm/s and acceleration works to about 10000mm/s2. These are maximums, not best quality!

You will need an assortment of M3 and M4 screws from 8mm to 20mm. A couple of M3 and M4 nuts. One M4 of 30mm or more for the tension adjustment. The design is for cap-head hex sockets.

Updated Design 2024.5.9:
I had a Y-Axis linear rail failure and it could be due to some binding from the X-Axis width. I've therefore moved my Y-Axis rails to below the frame and fitted the carriage with slotted screw holes that allow for a little adjustment in the X-Axis. The replaces the Y-Axis lower pieces but uses the same screws. The belt on this design is pinched between the bracket and the carriage. 
The left side has an additional screw hole to mount the Y-axis limit button (new part) and both sides offset the carriage a few mm towards the back of the machine to prevent them running off the rails at the front.  The 3 new files are named with “2004.5.9” and are white in the photos.

I've remodelled the Hoon design to make the parts easier to print and slightly easier to fit. I've also integrated a Zman style belt tensioner. These are new original models  using Hoon & Zman's ideas and dimensions. I also took Phil's fan duct and adapted it to fit the 12mm rails instead of 9mm

I've remodelled the head parts for the MGN12H linear rails and stock part cooling fan, stock breakout board, stock hotend and fan. The X-axis belt also attaches using a more traditional slot-mount instead of screw-down clips. I've included a hotend fan cover that's slimline and easy to print. 

My Y-Axis parts should be easier to install or update, as I've moved screws to be more accessible and the belt attached from the outside.

This video should give you an idea of how it fits together and what you can expect: