Shortened extruder platform. Tweaked spool holder. Reduced facet counts. Moved side joiners to rail segments from motor segments.

TODO.md

@@ -1,6 +1,5 @@
 TODO:
 ====
 
-- Screwless RAMPS motherboard mount.
 - Screwless mounts for limit switches.
 

cable_chain_mount_parts.scad

@@ -4,8 +4,8 @@ use <joiners.scad>
 use <cable_chain.scad>
 
 
-$fa = 1;
-$fs = 1;
+$fa = 2;
+$fs = 2;
 
 
 module cable_chain_joiner_mount()

config.scad

@@ -52,11 +52,14 @@ endstop_standoff     =  2; // mm
 
 // Mechanical endstop bare microswitch.
 endstop_hole_spacing =  9.5; // mm
-endstop_hole_inset   =  8;   // mm
-endstop_hole_hoff    = 10;   // mm
-endstop_click_voff   =  3;   // mm
+endstop_hole_inset   =  8.0; // mm
+endstop_hole_hoff    = 10.0; // mm
+endstop_click_voff   =  3.0; // mm
 endstop_screw_size   =  2.5; // mm
-endstop_standoff     =  2;   // mm
+endstop_standoff     =  1.0; // mm
+endstop_length       = 19.9; // mm
+endstop_thick        =  6.7; // mm
+endstop_depth        = 11.0; // mm
 
 // Standard Mk2b Heated Build Platform from RepRapDiscount.com
 hbp_width       = 215;   // mm
@@ -88,7 +91,7 @@ jhead_groove_diam   =  12.0;  // mm
 jhead_cap_height    =   8.2;  // mm
 jhead_cap_diam      =  12.0;  // mm
 
-extruder_length      = 150.0;  // mm
+extruder_length      = 130.0;  // mm
 extruder_thick       =   5.0;  // mm
 extruder_shaft_len   =  25.0;  // mm
 extruder_drive_diam  =  12.5;  // mm
@@ -132,7 +135,7 @@ printer_slop =   0.25;  // mm
 rail_spacing = platform_width - joiner_width*4 - 10;
 rail_width = rail_spacing + joiner_width*2;
 motor_mount_spacing=43+joiner_width+10;
-side_mount_spacing = platform_length-25;
+side_mount_spacing = platform_length+10*2;
 cantilever_length = (motor_rail_length+2*rail_length+2*platform_length-2*rail_height-2*rail_length-extruder_length-groove_height)/2;
 platform_z = rail_height+groove_height+rail_offset;
 motor_top_z = platform_z-platform_thick-rack_base-rack_height-gear_base-2;

cooling_fan_shroud_parts.scad

@@ -3,10 +3,10 @@ use <GDMUtils.scad>
 use <joiners.scad>
 
 
-$fa = 1;
+$fa = 2;
 $fs = 2;
 
-tilt = 15;
+tilt = 18;
 duct_h = cooling_duct_height - 8;
 
 module cooling_fan_shroud()
@@ -19,6 +19,7 @@ module cooling_fan_shroud()
 	yrot(-tilt) {
 		difference() {
 			union() {
+				// Top joiner
 				difference() {
 					rotate([90+tilt, 0, 90]) {
 						prerender(convexity=8) {
@@ -29,18 +30,19 @@ module cooling_fan_shroud()
 						cube(rail_height, center=true);
 					}
 				}
+
 				down(6+duct_h/2) {
 					right((cooling_fan_size+2*wall)/2-rail_height/2/2+extruder_fan_size) {
 						difference() {
 							union() {
-								up((cooling_fan_thick+wall)/2) {
+								up((cooling_fan_thick)/2) {
 									difference() {
-										rrect([cooling_fan_size+2*wall, cooling_fan_size+2*wall, duct_h+cooling_fan_thick+wall], r=10, center=true);
+										rrect([cooling_fan_size+2*wall, cooling_fan_size+2*wall, duct_h+cooling_fan_thick], r=10, center=true);
 										up(duct_h/2+0.05) {
 											zrot(45) {
 												difference() {
-													cube([cooling_fan_size*3, cooling_fan_size*3, cooling_fan_thick+wall], center=true);
-													cube([cooling_fan_size, cooling_fan_size, cooling_fan_thick+wall], center=true);
+													cube([cooling_fan_size*3, cooling_fan_size*3, cooling_fan_thick], center=true);
+													cube([cooling_fan_size, cooling_fan_size, cooling_fan_thick], center=true);
 												}
 											}
 										}
@@ -48,20 +50,28 @@ module cooling_fan_shroud()
 								}
 								yrot(-90) zrot(90) teardrop(r=cooling_fan_size/2+wall, h=duct_h, ang=duct_ang);
 							}
+
+							// Clear fan clip
 							up((duct_h+cooling_fan_thick+wall)/2+0.05) {
 								trapezoid([cooling_fan_size, cooling_fan_size], [cooling_fan_size-0.5, cooling_fan_size-0.5], h=cooling_fan_thick+wall, center=true);
 							}
-							yrot(-90) zrot(90) teardrop(r=cooling_fan_size/2, h=duct_h-2*wall, ang=duct_ang);
+
+							// Clear horiz duct
+							yrot(-90) zrot(90) teardrop(r=cooling_fan_size/2, h=duct_h-wall, ang=duct_ang);
 						}
+
+						// support columns aroundvertical fan duct
 						zring(r=cooling_fan_size/2+wall/2+0.05, n=20) {
 							cube([wall, wall, duct_h], center=true);
 						}
 					}
+
+					// Sidways top support struts
 					intersection() {
 						right(8.5) {
 							up(duct_h/2-2/2) {
 								xspread(10,n=5) {
-									cube([2, cooling_fan_size, wall+0.6], center=true);
+									cube([2, cooling_fan_size, wall/2+0.6], center=true);
 								}
 							}
 						}
@@ -69,15 +79,19 @@ module cooling_fan_shroud()
 							yrot(-90) zrot(90) teardrop(r=cooling_fan_size/2+wall, h=duct_h, ang=duct_ang);
 						}
 					}
+
+					// duct supports
 					left(cooling_fan_size*2) {
 						zrot_copies([-3.4, 3.4]) {
 							right(cooling_fan_size*2) {
-								trapezoid([cooling_fan_size*2, wall], [cooling_fan_size*1.5, wall*2], h=duct_h-wall/2, center=true);
+								trapezoid([cooling_fan_size*2, wall], [cooling_fan_size*1.5, wall*2], h=duct_h, center=true);
 							}
 						}
 					}
 				}
 			}
+
+			// Truncate exit tip
 			left(rail_height/2/2) {
 				left(200/2) cube(200, center=true);
 				down(duct_h+6) {
@@ -86,15 +100,19 @@ module cooling_fan_shroud()
 					}
 				}
 			}
+
+			// Clear vertical fan duct
 			down(6+duct_h/2) {
 				right((cooling_fan_size+2*wall)/2-rail_height/2/2+extruder_fan_size) {
 					up((wall+cooling_fan_thick+wall)/2+0.05) {
-						cylinder(h=duct_h+cooling_fan_thick+wall-wall+0.05, d=cooling_fan_size, center=true);
+						cylinder(h=duct_h+cooling_fan_thick+wall+0.05, d=cooling_fan_size, center=true);
 					}
 				}
 			}
 		}
 	}
+
+	// Fan
 	yrot(-tilt) {
 		down(6+duct_h/2) {
 			right((cooling_fan_size+2*wall)/2-rail_height/2/2+extruder_fan_size) {

drive_gear_parts.scad

@@ -3,8 +3,8 @@ use <GDMUtils.scad>
 use <publicDomainGearV1.1.scad>
 
 
-$fa = 1;
-$fs = 1.5;
+$fa = 2;
+$fs = 2;
 
 module drive_gear() {
 	shaft = motor_shaft_size + printer_slop;

extruder_fan_clip_parts.scad

@@ -3,8 +3,8 @@ use <GDMUtils.scad>
 use <joiners.scad>
 
 
-$fa = 1;
-$fs = 1.5;
+$fa = 2;
+$fs = 2;
 
 h = 6;
 thick = 8;

extruder_fan_shroud_parts.scad

@@ -3,7 +3,7 @@ use <GDMUtils.scad>
 use <joiners.scad>
 
 
-$fa = 1;
+$fa = 2;
 $fs = 2;
 
 module extruder_fan_shroud()

extruder_idler_parts.scad

@@ -4,8 +4,8 @@ use <NEMA.scad>
 use <joiners.scad>
 
 
-$fa=1;
-$fs=1;
+$fa = 2;
+$fs = 2;
 
 width = extruder_shaft_len/2;
 thick = 3;

extruder_motor_clip_parts.scad

@@ -4,8 +4,8 @@ use <NEMA.scad>
 use <joiners.scad>
 
 
-$fa=1;
-$fs=1;
+$fa = 2;
+$fs = 2;
 
 thick = 6;
 motor_width = nema_motor_width(17);

full_assembly.scad

@@ -211,7 +211,7 @@ module x_axis_slider_assembly(slidepos=0, explode=0, arrows=false)
 	platform_vert_off = rail_height+groove_height/2;
 
 	zrot(90) xy_motor_segment_assembly();
-	xspread(motor_rail_length+rail_length+2*explode) {
+	zring(r=(motor_rail_length+rail_length+2*explode)/2, n=2) {
 		zrot(90) rail_segment();
 	}
 
@@ -250,8 +250,10 @@ module y_axis_slider_assembly(slidepos=0, hide_endcaps=false, explode=0, arrows=
 	platform_vert_off = rail_height+groove_height/2;
 
 	xy_motor_segment_assembly();
-	yspread(motor_rail_length+rail_length+2*explode) {
-		rail_segment();
+	zrot(90) {
+		zring(r=(motor_rail_length+rail_length+2*explode)/2, n=2) {
+			zrot(90) rail_segment();
+		}
 	}
 	zrot(90) zring(r=(motor_rail_length+2*rail_length+4*explode)/2) {
 		if (hide_endcaps == false) {
@@ -418,8 +420,8 @@ module extruder_bridge_assembly(slidepos=0, explode=0, arrows=false)
 	back(extruder_length/2+rail_length+cantilever_length+2*explode)
 	down(platform_length/2-slidepos) {
 		extruder_assembly();
-		yspread(extruder_length+rail_length+2*explode) {
-			rail_segment();
+		zrot(90) zring(r=(extruder_length+rail_length+2*explode)/2, n=2) {
+			zrot(-90) rail_segment();
 		}
 		zrot(90) zring(r=(extruder_length+2*rail_length+2*cantilever_length+4*explode)/2) {
 			zrot(180) z_sled();

jhead_platform_parts.scad

@@ -4,7 +4,7 @@ use <NEMA.scad>
 use <joiners.scad>
 
 
-$fa = 1;
+$fa = 2;
 $fs = 2;
 
 
@@ -124,6 +124,8 @@ module jhead_platform()
 	h = rail_height;
 	thick = jhead_groove_thick;
 	motor_width = nema_motor_width(17);
+	idler_backside = (jhead_barrel_diam+8)/2+8;
+	idler_back_thick = 3;
 
 	color("SteelBlue")
 	prerender(convexity=10)
@@ -131,13 +133,14 @@ module jhead_platform()
 		difference() {
 			union() {
 				// Bottom.
-				up(thick/2)
+				up(thick/2) {
 					cube(size=[w, l, thick], center=true);
+				}
 
 				// Walls.
 				xspread(rail_spacing+joiner_width) {
 					up(h/6) {
-						cube(size=[joiner_width, l/2-5, h/3], center=true);
+						cube(size=[joiner_width, l/3-5, h/3], center=true);
 					}
 				}
 
@@ -163,25 +166,16 @@ module jhead_platform()
 				// Wall Triangles
 				zring(n=2) {
 					xflip_copy() {
-						up(h/2) {
-							fwd(l/2-l/6-10+0.05) {
+						up((h+groove_height)/2) {
+							fwd(l/2-l/2/2-0+0.05) {
 								right((rail_spacing+joiner_width)/2) {
-									thinning_brace(h=h, l=l/3, thick=joiner_width, strut=5);
+									thinning_brace(h=h+groove_height, l=l/2, thick=joiner_width, strut=groove_height/sqrt(2));
 								}
 							}
 						}
 					}
 				}
 
-				// Side support walls
-				yspread(l-2*10+4) {
-					up(h/5/2) {
-						difference() {
-							cube([w, 4, h/5], center=true);
-						}
-					}
-				}
-
 				// Jhead base
 				fwd(extruder_shaft_len/4/2) {
 					up((jhead_shelf_thick+jhead_groove_thick)/2) {
@@ -196,7 +190,7 @@ module jhead_platform()
 
 				// Lower idler mount block
 				up(jhead_groove_thick+jhead_shelf_thick) {
-					left((jhead_barrel_diam+8)/2+6) {
+					xspread(jhead_barrel_diam+8+9) {
 						up(5/2) {
 							fwd(2/2) {
 								cube([15, extruder_shaft_len/2+2, 5], center=true);
@@ -304,7 +298,7 @@ module jhead_platform()
 				}
 
 				// Wire access slot
-				back(extruder_length/7) {
+				back(extruder_length/4-extruder_fan_size/2+8/2) {
 					hull() {
 						xspread(w*0.5) {
 							cylinder(h=jhead_shelf_thick+jhead_groove_thick+1, d=8, center=true);
@@ -314,26 +308,15 @@ module jhead_platform()
 			}
 
 			// Bottom idler holder
-			backside = (jhead_barrel_diam+8)/2+8;
-			up(jhead_groove_thick+3+printer_slop/2) {
-				left(backside-3) {
-					yrot_copies([0,-10]) {
-						difference() {
-							union() {
-								yrot(-45) {
-									xrot(90) cylinder(h=extruder_shaft_len/2+printer_slop, r=3+printer_slop/2, center=true);
-									up(3+printer_slop) {
-										cube([2*3+printer_slop, extruder_shaft_len/2+printer_slop, 2*3+printer_slop], center=true);
-									}
+			xflip_copy() {
+				up(jhead_groove_thick+idler_back_thick+printer_slop/2) {
+					left(idler_backside-idler_back_thick) {
+						teardrop(r=idler_back_thick+printer_slop/2, h=extruder_shaft_len/2+printer_slop/2, ang=40, $fs=1);
+						yrot_copies([0,-8]) {
+							left((idler_back_thick+printer_slop/2)/2) {
+								up(50/2) {
+									cube([idler_back_thick+printer_slop/2, extruder_shaft_len/2+printer_slop/2, 50], center=true);
 								}
-								left(3+printer_slop/2) {
-									up(motor_width/2) {
-										cube([2*3+printer_slop, extruder_shaft_len/2+printer_slop, motor_width], center=true);
-									}
-								}
-							}
-							left(3+printer_slop/2+(extruder_shaft_len+1)/2) {
-								cube(extruder_shaft_len+1, center=true);
 							}
 						}
 					}

joiners.scad

@@ -24,7 +24,7 @@ module half_joiner_clear(h=20, w=10, a=30, clearance=0)
 
 
 
-module half_joiner(h=20, w=10, l=10, a=30, screwsize=3, guides=true, slop=printer_slop)
+module half_joiner(h=20, w=10, l=10, a=30, screwsize=undef, guides=true, slop=printer_slop)
 {
 	dmnd_height = h*1.0;
 	dmnd_width = dmnd_height*tan(a);
@@ -58,10 +58,12 @@ module half_joiner(h=20, w=10, l=10, a=30, screwsize=3, guides=true, slop=printe
 
 			// Guide ridges.
 			if (guides == true) {
-				grid_of(xa=[-(w/6-slop), (w/6-slop)]) {
+				xspread(w/3-slop*2) {
 					// Guide ridge.
-					scale([0.75, 1, 2]) yrot(45)
-						cube(size=[guide_size/sqrt(2), guide_width, guide_size/sqrt(2)], center=true);
+					fwd(0.05/2) {
+						scale([0.75, 1, 2]) yrot(45)
+							cube(size=[guide_size/sqrt(2), guide_width+0.05, guide_size/sqrt(2)], center=true);
+					}
 
 					// Snap ridge.
 					scale([0.25, 0.5, 1]) zrot(45)
@@ -80,7 +82,7 @@ module half_joiner(h=20, w=10, l=10, a=30, screwsize=3, guides=true, slop=printe
 
 
 
-module half_joiner2(h=20, w=10, l=10, a=30, screwsize=3, guides=true)
+module half_joiner2(h=20, w=10, l=10, a=30, screwsize=undef, guides=true)
 {
 	difference() {
 		union () {
@@ -102,7 +104,7 @@ module half_joiner2(h=20, w=10, l=10, a=30, screwsize=3, guides=true)
 
 
 
-module joiner(h=40, w=10, l=10, a=30, screwsize=3, guides=true, slop=printer_slop)
+module joiner(h=40, w=10, l=10, a=30, screwsize=undef, guides=true, slop=printer_slop)
 {
 	union() {
 		translate([0,0,h/4])
@@ -125,7 +127,7 @@ module joiner_clear(h=40, w=10, a=30, clearance=0)
 
 
 
-module joiner_pair(spacing=100, h=40, w=10, l=10, a=30, screwsize=3, guides=true)
+module joiner_pair(spacing=100, h=40, w=10, l=10, a=30, screwsize=undef, guides=true)
 {
 	yrot_copies([0,180]) {
 		translate([spacing/2, 0, 0]) {
@@ -149,7 +151,7 @@ module joiner_pair_clear(spacing=100, h=40, w=10, a=30, clearance=0)
 
 
 
-module joiner_quad(xspacing=100, yspacing=50, h=40, w=10, l=10, a=30, screwsize=3, guides=true)
+module joiner_quad(xspacing=100, yspacing=50, h=40, w=10, l=10, a=30, screwsize=undef, guides=true)
 {
 	zrot_copies([0,180]) {
 		translate([0, yspacing/2, 0]) {

lifter_lock_nut_parts.scad

@@ -3,8 +3,8 @@ use <GDMUtils.scad>
 use <acme_screw.scad>
 
 
-$fa = 1;
-$fs = 1;
+$fa = 2;
+$fs = 2;
 
 module lifter_lock_nut()
 {

lifter_rod_coupler_parts.scad

@@ -2,7 +2,7 @@ include <config.scad>
 use <GDMUtils.scad>
 use <acme_screw.scad>
 
-$fa = 1;
+$fa = 2;
 $fs = 2;
 
 

motor_mount_plate_parts.scad

@@ -4,15 +4,16 @@ use <NEMA.scad>
 use <joiners.scad>
 
 
-$fa=1;
-$fs=1;
+$fa = 2;
+$fs = 2;
 
 
 module motor_mount_plate()
 {
 	l = motor_length/2;
-	thick = 4;
+	thick = 6;
 	motor_width = nema_motor_width(17);
+	clip_wall = 2;
 
 	color("Teal")
 	prerender(convexity=10)
@@ -20,7 +21,9 @@ module motor_mount_plate()
 		union() {
 			up(l) {
 				difference() {
-					cube(size=[motor_mount_spacing+joiner_width, rail_height, thick], center=true);
+					down(thick/2-2) {
+						cube(size=[motor_mount_spacing+joiner_width, rail_height, thick], center=true);
+					}
 					zrot(90) nema17_mount_holes(depth=thick+1, l=0, slop=printer_slop);
 					down(l) cube([motor_width, motor_width, motor_length], center=true);
 				}
@@ -29,44 +32,46 @@ module motor_mount_plate()
 			// Joiners
 			xrot(-90) joiner_pair(spacing=motor_mount_spacing, h=rail_height, w=joiner_width, l=l, a=joiner_angle);
 
-			// Standoffs
 			zrot_copies([0, 180]) {
-				right(motor_mount_spacing/2+joiner_width/2+endstop_standoff/2-0.05) {
-					up(l+thick/2-endstop_hole_inset) {
+				right((motor_mount_spacing+joiner_width)/2) {
+					up(l+thick/2-2/2) {
 						fwd(endstop_hole_hoff) {
-							yspread(endstop_hole_spacing) {
-								difference() {
-									yrot(90) {
-										cylinder(
-											r1=endstop_screw_size*1.1/2/cos(30)+1+endstop_standoff,
-											r2=endstop_screw_size*1.1/2/cos(30)+1,
-											h=endstop_standoff+0.05,
-											center=true,
-											$fn=24
-										);
-									}
-									up(endstop_hole_inset+endstop_screw_size) {
-										cube(size=[endstop_standoff+2, endstop_screw_size*4, endstop_screw_size*2], center=true);
-									}
-								}
-							}
-						}
-					}
-				}
-			}
-		}
 
-		zrot_copies([0, 180]) {
-			right(motor_mount_spacing/2+endstop_standoff/2-0.05) {
-				up(l+thick/2-endstop_hole_inset) {
-					fwd(endstop_hole_hoff) {
-						yspread(endstop_hole_spacing) {
-							yrot(90) cylinder(r=endstop_screw_size*1.1/2, h=joiner_width+endstop_standoff+0.1, center=true, $fn=18);
-							left(joiner_width/2+1.1) {
-								scale([1.1, 1.1, 1.1]) {
-									yrot(90) zrot(90) metric_nut(size=endstop_screw_size, hole=false);
+							// limit switch clips
+							down(endstop_depth/2) {
+								right(endstop_standoff/2-0.05/2) {
+									cube([endstop_standoff+0.05, endstop_length+2*clip_wall, endstop_depth], center=true);
+									down(endstop_depth/2+clip_wall/2) {
+										trapezoid([2, endstop_length+2*clip_wall], [endstop_standoff+3, endstop_length+2*clip_wall], h=clip_wall, center=true);
+									}
+								}
+								right(endstop_standoff) {
+									right((endstop_thick+clip_wall-0.05)/2) {
+										yflip_copy() {
+											fwd((endstop_length+clip_wall)/2) {
+												cube([endstop_thick+clip_wall+0.05, clip_wall, endstop_depth], center=true);
+
+												// Clip ridge
+												right(endstop_thick/2) {
+													back_half() {
+														yrot(90) trapezoid([endstop_depth, clip_wall+1], [endstop_depth, clip_wall], h=clip_wall, center=true);
+													}
+												}
+											}
+										}
+									}
 								}
 							}
+
+							// limit switch snap bumps
+							down(endstop_hole_inset) {
+								right(endstop_standoff) {
+									yspread(endstop_hole_spacing) {
+										scale([0.5,1,1]) sphere(d=endstop_screw_size, center=true, $fn=12);
+									}
+								}
+							}
+
 						}
 					}
 				}
@@ -80,9 +85,11 @@ module motor_mount_plate()
 
 module motor_mount_plate_parts() { // make me
 	up(motor_length/2+2) {
-		xspread(55, n=2) {
-			yspread(80, n=2) {
-				zrot(90) yrot(180) motor_mount_plate();
+		yspread(55) {
+			zring(r=85/2, n=2) {
+				back(-3.5) {
+					yrot(180) motor_mount_plate();
+				}
 			}
 		}
 	}

rail_segment_parts.scad

@@ -6,6 +6,7 @@ use <joiners.scad>
 module rail_segment()
 {
 	fillet = 1;
+	side_joiner_len = 10;
 
 	color([0.9, 0.7, 1.0])
 	prerender(convexity=20)
@@ -46,6 +47,19 @@ module rail_segment()
 						}
 					}
 				}
+
+				// Side half joiners
+				up(rail_height/2/2) {
+					back(rail_length/2-10) {
+						zring(r=rail_spacing/2+joiner_width+side_joiner_len, n=2) {
+							zrot(-90) {
+								chamfer(chamfer=3, size=[joiner_width, 2*(side_joiner_len+joiner_width/2), rail_height/2], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]]) {
+									half_joiner2(h=rail_height/2, w=joiner_width, l=side_joiner_len+joiner_width/2, a=joiner_angle);
+								}
+							}
+						}
+					}
+				}
 			}
 
 			// Rail grooves.

rail_xy_motor_segment_parts.scad

@@ -21,15 +21,18 @@ module rail_xy_motor_segment()
 						union() {
 							yrot(90)
 								sparse_strut(h=rail_width, l=motor_rail_length, thick=rail_thick, maxang=45, strut=10, max_bridge=500);
-							up((motor_top_z-motor_length+4-rail_thick)/2) {
-								cube(size=[motor_mount_spacing+joiner_width, 30+20, motor_top_z-motor_length+4], center=true);
+							up((motor_top_z-motor_length+6-rail_thick)/2) {
+								cube(size=[motor_mount_spacing+joiner_width, 30+20, motor_top_z-motor_length+6], center=true);
 							}
 						}
-						cube(size=[motor_mount_spacing-joiner_width, 30, motor_length], center=true);
+						cube(size=[motor_mount_spacing-joiner_width, 20, motor_length], center=true);
 
 						// Clearance for NEMA17 stepper motor
 						up(motor_top_z-rail_thick/2) {
-							down(motor_length/2) cube(size=[motor_width, motor_width, motor_length], center=true);
+							down(motor_length/2) {
+								cube(size=[motor_width, motor_width, motor_length], center=true);
+								cube(size=[20, motor_rail_length/2+10, motor_length], center=true);
+							}
 						}
 					}
 				}
@@ -115,26 +118,12 @@ module rail_xy_motor_segment()
 				joiner_quad_clear(xspacing=rail_spacing+joiner_width, yspacing=motor_rail_length, h=rail_height, w=joiner_width, clearance=5, a=joiner_angle);
 			}
 
-			// Clear space for side mount joiners.
-			zring(r=0,n=2) {
-				right(rail_width/2-5) {
-					up(rail_height/2/2) {
-						right(side_joiner_len+joiner_width/2) {
-							left(platform_length/4) {
-								zrot(-90) half_joiner_clear(h=rail_height/2, w=joiner_width, l=side_joiner_len, a=joiner_angle);
-							}
-							right(platform_length/4) {
-								zrot(-90) half_joiner_clear(h=rail_height/2, w=joiner_width, l=side_joiner_len, a=joiner_angle, slop=printer_slop);
-							}
-						}
-					}
-				}
-			}
-
 			// Side wiring access hole
 			up(10/2+rail_thick) {
 				xspread(rail_width-joiner_width) {
-					cube(size=[joiner_width+1, 16, 10], center=true);
+					yspread(motor_rail_length-2*30) {
+						cube(size=[joiner_width+1, 16, 10], center=true);
+					}
 				}
 			}
 		}
@@ -143,30 +132,6 @@ module rail_xy_motor_segment()
 		up(rail_height/2) {
 			joiner_quad(xspacing=rail_spacing+joiner_width, yspacing=motor_rail_length, h=rail_height, w=joiner_width, l=13, a=joiner_angle);
 		}
-
-		// Side mount joiners.
-		zring(n=2) {
-			right(rail_width/2-5) {
-				up(rail_height/2/2) {
-					right(side_joiner_len+joiner_width/2) {
-						fwd(side_mount_spacing/2) {
-							zrot(-90) {
-								chamfer(chamfer=joiner_width/3, size=[joiner_width, side_joiner_len*4, rail_height/2], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]]) {
-									half_joiner2(h=rail_height/2, w=joiner_width, l=side_joiner_len+joiner_width/2, a=joiner_angle);
-								}
-							}
-						}
-						back(side_mount_spacing/2) {
-							zrot(-90) {
-								chamfer(chamfer=joiner_width/3, size=[joiner_width, side_joiner_len*4, rail_height/2], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]]) {
-									half_joiner2(h=rail_height/2, w=joiner_width, l=side_joiner_len+joiner_width/2, a=joiner_angle, slop=printer_slop);
-								}
-							}
-						}
-					}
-				}
-			}
-		}
 	}
 }
 //!rail_xy_motor_segment();

rail_z_motor_segment_parts.scad

@@ -128,19 +128,6 @@ module rail_z_motor_segment()
 		up(rail_height/2) {
 			joiner_quad(xspacing=rail_spacing+joiner_width, yspacing=motor_rail_length+0.05, h=rail_height, w=joiner_width, l=13, a=joiner_angle);
 		}
-
-		// Side mount joiners.
-		up(rail_height/2/2) {
-			back(side_mount_spacing/2) {
-				xflip_copy() {
-					right(rail_width/2+side_joiner_len) {
-						zrot(-90) {
-							half_joiner2(h=rail_height/2, w=joiner_width, l=side_joiner_len+joiner_width/2, a=joiner_angle);
-						}
-					}
-				}
-			}
-		}
 	}
 }
 //!rail_z_motor_segment();

rambo_mount_parts.scad

@@ -3,7 +3,7 @@ use <GDMUtils.scad>
 use <joiners.scad>
 
 
-$fa = 1;
+$fa = 2;
 $fs = 2;
 
 

ramps_mount_parts.scad

@@ -3,7 +3,7 @@ use <GDMUtils.scad>
 use <joiners.scad>
 
 
-$fa = 1;
+$fa = 2;
 $fs = 2;
 
 
@@ -14,7 +14,7 @@ board_thick         =  50.0;  // mm
 
 
 // l = board_length + rail_height + 5;
-l = board_length + 5;
+l = board_length + 10;
 joiner_length = board_thick + rail_thick;
 
 
@@ -53,7 +53,7 @@ module ramps_mount() {
 
 			// Motherboard standoffs
 			fwd(joiner_length-10/2) {
-				up(l/2) {
+				up(l/2+5/2) {
 					xspread(board_width) {
 						cube([5, rail_thick+10, 10], center=true);
 					}
@@ -65,7 +65,7 @@ module ramps_mount() {
         }
 
 		// Motherboard clip clearance
-		up(l/2) {
+		up(l/2+5/2) {
 			fwd(joiner_length-10/2-2) {
 				xrot(-90) trapezoid([board_width, board_length], [board_width-0.5, board_length-0.5], h=10);
 			}

spool_holder_parts.scad

@@ -3,8 +3,8 @@ use <GDMUtils.scad>
 use <joiners.scad>
 
 
-$fa = 1;
-$fs = 1.5;
+$fa = 2;
+$fs = 2;
 
 module spool_holder()
 {
@@ -29,6 +29,12 @@ module spool_holder()
 							}
 						}
 					}
+
+					top_half() {
+						right(rail_height/2) {
+							yrot(90) trapezoid([spool_holder_length/2, joiner_width], [10, joiner_width], h=groove_height);
+						}
+					}
 				}
 
 				// Back joiner

xy_joiner_parts.scad

@@ -27,11 +27,11 @@ module xy_joiner()
 		// Snap-tab joiners.
 		intersection() {
 			union() {
-				translate([0,0,-platform_height/2]) {
+				down(platform_height/2) {
 					joiner_pair(spacing=platform_width-joiner_width, h=platform_height, w=joiner_width, l=joiner_length, a=joiner_angle);
 				}
-				translate([0,0,rail_height/4]) {
-					grid_of(count=2, spacing=platform_width-joiner_width) {
+				up(rail_height/4) {
+					xspread(platform_width-joiner_width) {
 						half_joiner2(h=rail_height/2, w=joiner_width, l=joiner_length, a=joiner_angle);
 					}
 				}
@@ -47,12 +47,7 @@ module xy_joiner()
 		back(hoff) {
 			difference() {
 				up(rail_height/2/2) {
-					right(side_mount_spacing/2) {
-						chamfer(chamfer=3, size=[joiner_width, 2*(hoff+joiner_length), rail_height/2], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]]) {
-							half_joiner(h=rail_height/2, w=joiner_width, l=hoff+joiner_length, a=joiner_angle);
-						}
-					}
-					left(side_mount_spacing/2) {
+					xspread(side_mount_spacing) {
 						chamfer(chamfer=3, size=[joiner_width, 2*(hoff+joiner_length), rail_height/2], edges=[[0,0,0,0], [1,1,0,0], [0,0,0,0]]) {
 							half_joiner(h=rail_height/2, w=joiner_width, l=hoff+joiner_length, a=joiner_angle, slop=printer_slop);
 						}
@@ -60,7 +55,7 @@ module xy_joiner()
 				}
 				up(rail_height/2/2) {
 					fwd((hoff+joiner_width)/2) {
-						cube([side_mount_spacing+2*joiner_width, 15, 10], center=true);
+						cube([side_mount_spacing+2*joiner_width, hoff*3/4, 10], center=true);
 					}
 				}
 			}

xy_sled_parts.scad

@@ -4,8 +4,8 @@ use <joiners.scad>
 use <publicDomainGearV1.1.scad>
 
 
-$fa = 1;
-$fs = 1.5;
+$fa = 2;
+$fs = 2;
 
 module herringbone_rack(l=100, h=10, w=10, tooth_size=5, CA=30)
 {
@@ -93,7 +93,8 @@ module xy_sled()
 						yspread(platform_length-slider_len-15, n=1) {
 							up(rail_offset+groove_height/2) {
 								translate([-joiner_width/2, 0, 0]) {
-									circle_of(n=2, r=joiner_width/2+printer_slop, rot=true) {
+									circle_of(n=2, r=joiner_width/2+printer_slop/2, rot=true) {
+
 										// Slider base
 										translate([15/2-9, 0, -groove_height-printer_slop]) {
 											difference() {

yz_joiner_parts.scad

@@ -28,11 +28,11 @@ module yz_joiner()
 						back(rail_thick/2) {
 							zrot(90) {
 								if (wall_style == "crossbeams")
-									sparse_strut(h=rail_height+groove_height, l=rail_width-joiner_width, thick=rail_thick, strut=5);
+									sparse_strut(h=rail_height+groove_height, l=rail_width-joiner_width/2, thick=rail_thick, strut=5);
 								if (wall_style == "thinwall")
-									thinning_wall(h=rail_height+groove_height, l=rail_width-joiner_width, thick=rail_thick, strut=rail_thick, bracing=true);
+									thinning_wall(h=rail_height+groove_height, l=rail_width-joiner_width/2, thick=rail_thick, strut=rail_thick, bracing=true);
 								if (wall_style == "corrugated")
-									corrugated_wall(h=rail_height+groove_height, l=rail_width-joiner_width, thick=rail_thick, strut=rail_thick, wall=3);
+									corrugated_wall(h=rail_height+groove_height, l=rail_width-joiner_width/2, thick=rail_thick, strut=rail_thick, wall=3);
 							}
 						}
 					}
@@ -47,7 +47,7 @@ module yz_joiner()
 										sparse_strut(l=platform_length-joiner_length+1, h=rail_height+rail_thick, thick=joiner_width, strut=5);
 								if (wall_style == "thinwall")
 									up((rail_height+rail_thick)/2)
-										thinning_wall(l=platform_length-joiner_length+1, h=rail_height+rail_thick, thick=joiner_width, strut=rail_thick, bracing=true);
+										thinning_wall(l=platform_length-joiner_length+1, h=rail_height+rail_thick, thick=joiner_width, strut=rail_thick, bracing=false);
 								if (wall_style == "corrugated")
 									up(rail_height/2)
 										corrugated_wall(l=platform_length-joiner_length+1, h=rail_height, thick=joiner_width, strut=rail_thick, wall=3);
@@ -93,6 +93,11 @@ module yz_joiner()
 				translate([0, rail_height/2, rail_height+groove_height+0.05]) {
 					xrot(90) joiner_pair_clear(spacing=rail_spacing+joiner_width, h=rail_height, w=joiner_width+0.001, clearance=5, a=joiner_angle);
 				}
+				
+				// Wiring access hole
+				up(rail_thick+rail_height/4/2) {
+					cube([16, joiner_width*3, rail_height/4], center=true);
+				}
 			}
 
 			// Front joiners.

z_sled_parts.scad

@@ -4,8 +4,8 @@ use <joiners.scad>
 use <acme_screw.scad>
 
 
-$fa = 1;
-$fs = 1.5;
+$fa = 2;
+$fs = 2;
 
 module z_sled()
 {
@@ -58,7 +58,7 @@ module z_sled()
 						fwd(10/2) {
 							yspread(platform_length-slider_len-10, n=1) {
 								up(groove_height/2+offcenter) {
-									zring(n=2, r=joiner_width/2+printer_slop+2) {
+									zring(n=2, r=joiner_width/2+printer_slop/2+2) {
 										xs = 1 + 4/(groove_height*tan(groove_angle));
 										scale([xs*tan(groove_angle),1,xs]) {
 											difference() {
@@ -111,17 +111,6 @@ module z_sled()
 			}
 		}
 
-		// Side joiners
-		xflip_copy() {
-			up(rail_height/2/2) {
-				back(joiner_width/2) {
-					right((platform_width-5)/2) {
-						zrot(-90) half_joiner2(h=rail_height/2, w=joiner_width, clearance=5, a=joiner_angle, slop=printer_slop);
-					}
-				}
-			}
-		}
-
 		up(offcenter+groove_height+platform_thick-2) {
 			difference() {
 				union() {