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Greg's Wade extruder for Prusa i3 redux

I like misan's modified Greg's for Prusa i3 (and Bob is my uncle), but I wanted a few small changes, starting with not having the head of the idler hinge bolt hit the X carriage (the newer one, as shown in the photo). Here's a list, in no particular order, of the changes I've made:

  • Set base extra depth to 2mm so the head of the idler hinge bolt doesn't interfere with the X carriage.
  • Added a small thumb-grip to the top of the idler.
  • Increased hole for 608 bearing from 22.3 to 23mm because they are always too tight.
  • The forward-foot of the base was shortened by 10mm. This also allows for fan mount to fit on standard x carriage (described below)
  • The legacy mounting holes were removed. I don't need them, and they encourage cracking of the base.
  • Added recessed M3 nut traps for JHead (wildseyed) mount on the X-carriage side of the body.
  • Radius of the nut trap built into the idler hinge was increased by .25mm because mine are always too small.
  • Added a OSH logo (http://www.thingiverse.com/thing:27097) tucked into the space under the motor mount, which makes the extruder 18% more awesome and gaurantees your prints all come out better.
  • The thickness of the bearing washer was changed from 1mm to 3 times the layer_thickness.
  • I added a 40mm fan holder to the design. Because I made the foot of the extruder shorter, I can mount this to the spare hole of the X carriage, and it doesn't increase the width of the whole assembly at all. Also, it tilts which is nicer than mounting a 30mm fan straight to the extruder.
  • The radius of recessed carriage mounting holes was increased by .1mm so that M3 bolts go in nicer.
  • The beveled guide inside the idler was moved outward a little, because it's too tight.
  • The cutout for the 20mm idler bolt (M8) was increased in radius to M8/2.

There is also a separate openscad file and STL for a 30mm fan. The fan in that scad file is parametric, so you should be able to adjust it for other size fans also.

  • I have also uploaded a version of the base with the holes put back (sorry, can't fit the fan mount then but is needed for some types of hot-ends), and also a version of the idler with widened holes that work better for M4x60mm screws (easier to come by than M3x60mm)