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Summary
An alternative design for the RepRap Darwin Z endstop. It allows the machine to home the z-axis away from the workpiece, so that homing is always a safe operation, regardless of what state the machine is in. More details in my blog: http://hydraraptor.blogspot.com/2008/08/alternative-z-endstop.html
Instructions
Print the parts with a RepRap. If your ABS is not opaque to IR you will need to paint it with something that is or wrap it in tin foil. I used black BBQ paint.
Fasten the tab to a bed corner bracket with two M5x15 bolts. Attach the opto PCB to the opto bracket with two M3x12 bolts and fasten the bracket to a vertical post with an M4x20 bolt.
Adjust the opto bracket angle so that the tab clears the slot and set its height to where you want the z-limit to be.