Shrunk jhead_platform to fit in the previously established build volume.

STLs/sled_endcap_parts.stl

@@ -597,7 +597,7 @@ solid Model
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@@ -1711,14 +1711,14 @@ solid Model
     outer loop
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       vertex -13.793 65 5
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       vertex -10 65 5
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   facet normal 1 0 0
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-      vertex -13.793 -45.5 12.45
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   facet normal 1 0 0
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       vertex -13.793 65 5
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   facet normal 0 1 0
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@@ -1781,7 +1781,7 @@ solid Model
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       vertex -10 65 5
       vertex -10 65 37
-      vertex -13.793 65 12.45
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   facet normal 0 1 0
@@ -2890,6 +2890,125 @@ solid Model
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+  facet normal 0 0 1
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+  facet normal 0 0 1
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STLs/xy_joiner_parts.stl

@@ -2,7 +2,7 @@ solid Model
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@@ -38,13 +38,13 @@ solid Model
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@@ -87,14 +87,14 @@ solid Model
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STLs/z_rail_parts.stl

@@ -1483,13 +1483,6 @@ solid Model
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@@ -1518,6 +1511,13 @@ solid Model
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@@ -1945,6 +1945,13 @@ solid Model
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@@ -2876,13 +2883,6 @@ solid Model
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bridge_segment_parts.scad

@@ -69,15 +69,29 @@ module bridge_segment(explode=0, connectby="")
 								}
 							}
 
-							// Side Supports
+							// Wide end cross support
+							up(rail_height/2) {
+								back(l/2-joiner_width/2) {
+									difference() {
+										zrot(90) thinning_wall(l=rail_spacing+2*joiner_width-0.1, thick=joiner_width, h=rail_height, strut=platform_thick);
+										down(rail_height/2-rail_thick-10/2-0.05) {
+											cube(size=[16, 11, 10], center=true);
+										}
+									}
+								}
+							}
+
+							// Center cross support
 							up(wall_h/2) {
-								yspread(l-2*5.5-5) {
+								fwd((l-2*5.5-5)/2) {
 									difference() {
 										cube(size=[spacing-0.1, 4, wall_h], center=true);
 										down(wall_h/2-rail_thick-10/2-0.05) cube(size=[16, 11, 10], center=true);
 									}
 								}
 							}
+
+							// Thin end cross support
 							up(wall_h/2) {
 								difference() {
 									cube(size=[spacing-0.1, 4, wall_h], center=true);
@@ -85,13 +99,13 @@ module bridge_segment(explode=0, connectby="")
 								}
 							}
 
-							// Bracing
+							// Triangle Bracing
 							up(rail_height/2-0.05) {
 								xspread(spacing) {
 									yflip_copy() {
-										back(l/2-10) {
+										back(l/2-6) {
 											front_half() {
-												trapezoid([2*lifter_tooth_depth, rail_height/2], [2*lifter_tooth_depth, 0.1], h=rail_height/4, center=false);
+												trapezoid([2*lifter_tooth_depth, rail_height], [2*lifter_tooth_depth, 0.1], h=rail_height/2, center=false);
 											}
 										}
 									}
@@ -102,25 +116,23 @@ module bridge_segment(explode=0, connectby="")
 						// Clear space for joiners.
 						up(rail_height/2) {
 							fwd(l/2-0.05) zrot(180) xspread(spacing) joiner_clear(h=rail_height, w=joiner_width, clearance=1, a=joiner_angle);
-							back(l/2-0.05) xspread(spacing) yrot(180) joiner_clear(h=rail_height, w=joiner_width, clearance=1, a=joiner_angle);
+							back(l/2-0.05) xspread(rail_spacing+joiner_width) yrot(180) joiner_clear(h=rail_height, w=joiner_width, clearance=1, a=joiner_angle);
 						}
 					}
 
 					// Snap-tab joiners.
 					up(rail_height/2+0.05) {
 						fwd(l/2) zrot(180) xspread(spacing) joiner(h=rail_height, w=joiner_width, l=10, a=joiner_angle);
-						back(l/2) xspread(spacing) yrot(180) joiner(h=rail_height, w=joiner_width, l=10, a=joiner_angle);
+						back(l/2) xspread(rail_spacing+joiner_width) yrot(180) joiner(h=rail_height, w=joiner_width, l=10, a=joiner_angle);
 					}
 				}
 
 				// Clear space for Side half joiners
 				up(rail_height/2/2) {
-					yspread(l-2*joiner_width-1-0.05) {
+					fwd((l-2*joiner_width-1-0.05)/2) {
 						zring(r=spacing/2+joiner_width/2+side_joiner_len+0.05, 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_joiner_clear(h=rail_height/2, w=joiner_width, a=joiner_angle, clearance=0);
-								}
+								half_joiner_clear(h=rail_height/2, w=joiner_width, a=joiner_angle, clearance=0);
 							}
 						}
 					}
@@ -128,7 +140,7 @@ module bridge_segment(explode=0, connectby="")
 			}
 			// Side half joiners
 			up(rail_height/2/2) {
-				yspread(l-2*joiner_width-1-0.05) {
+				fwd((l-2*joiner_width-1-0.05)/2) {
 					zring(r=spacing/2+joiner_width/2+side_joiner_len+0.1, 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]]) {

config.scad

@@ -130,7 +130,7 @@ gear_backlash = 0;  // mm
 
 // Commonly used derived values.  Don't change these.
 pi = 3.141592653589793236+0.0;
-extruder_length = motor_rail_length + 2*lifter_screw_pitch;
+extruder_length = motor_rail_length;
 shaft_clear = max(0, motor_shaft_length - (rack_height + gear_base));
 rail_offset = shaft_clear + platform_thick + rack_height/2 + 2.0;
 rail_spacing = platform_width - joiner_width*4 - 10;

docs/assembly/index.html

@@ -81,7 +81,7 @@ UL {
 <table><tr><td class="befor"><img src="y_axis_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="y_axis_assembly_4_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 5</h3>
-<div class="desc">Slide the Y sled partial assembly onto the Y axis rails assembly, so that it is centered.</div>
+<div class="desc">Slide the Y sled partial assembly onto the Y axis rails assembly, so that it is centered.  The gear rack should slide between the limit switch on the left, and the drive gear.  Adjust the drive gear if necessary, so that it aligns exactly with the herringbone rack.</div>
 <table><tr><td class="befor"><img src="y_axis_assembly_5_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="y_axis_assembly_5_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 6</h3>
@@ -89,7 +89,7 @@ UL {
 <table><tr><td class="befor"><img src="y_axis_assembly_6_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="y_axis_assembly_6_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 7</h3>
-<div class="desc">Join a rail endcap to each end of the Y axis with completed sled assembly.</div>
+<div class="desc">Optionally join a rail endcap to each end of the Y axis.</div>
 <table><tr><td class="befor"><img src="y_axis_assembly_7_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="y_axis_assembly_7_after.png"></td></tr></table>
 </li>
 </ul>
@@ -121,7 +121,7 @@ UL {
 <table><tr><td class="befor"><img src="x_axis_assembly_3_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_3_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 4</h3>
-<div class="desc">Join an X sled endcap assembly to one end of the X sled central assembly.</div>
+<div class="desc">Join an X-Y joiner endcap to one end of the X sled central assembly.</div>
 <table><tr><td class="befor"><img src="x_axis_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_4_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 5</h3>