I designed this little adjustable adapter plate to mount my DC42 Mini height sensor board to my E3D X-axis Carriage where the BLTouch would normally be installed.
This works out great as the large hole allows a screwdriver to be inserted to raise and lower the sensor. I couldn't find any mounts for this board that allowed for adjustment and fiddling with the Z-Axis Offset can be a real pain.
It is also designed to protect the sensor from the majority of filament disasters as the board as mounted facing away from the extruder.
The Mount (included) has been remixed from this design as I lost ~20mm on the left due to my X-axis endstop being too far over.
Other hardware required:
1 X MINI DIFFERENTIAL IR HEIGHT SENSOR
3 X M3 hex nuts
2 X M3 x 10mm hex bolts
1 X M3 x ~25mm hex bolt (+/- 5mm)
1 X M3 washer (optional)
1 X 5mm OD / 3.3mm ID x 15mm spring (spare bed spring)
I printed the sensor mount piece laying flat with supports as I was experiencing issues with it breaking when printed standing but without supports.
Printed with 100% infill for rigidity - may not need.
Cleanup and assembly
Depending on how well your printer handles supports, you may need to sand the sensor board a bit to get it to slide smoothly inside the upper mounting piece.
Don't overdo it as too much clearance could cause the lower piece to not fit snugly and cause your sensor to not give repeatable readings.
Insert the two hex nuts into the hex shaped recesses in the top piece. They should fit snugly so as not to fall out.
Insert a hex nut into the slot on the lower half.
Slide the lower half up into the upper half.
Insert the long bolt through the hole in the top of the mount and capture the spring in between the two parts.
Thread the bolt into the nut and apply some tension on the spring.
Mount the sensor into the lower piece with the capacitor facing out.
Mount the entire assembly to the x-axis carriage using the 10mm bolts being careful not to knock the hex nuts out of their holes.
Sketch in Fusion 360
Transfer your dimensions from paper to a sketch in Fusion 360
BLTouch mounting flange sketch
IR Sensor mounting plate and overall height
Bringing it all together
Push, pull, cleanse, fold, and manipulate.
Extrude the sketches into two bodies.
Push in a small amount of clearance, check the fit using the section analysis.
Print out the first run and test everything.
Make changes until everything is perfect and five iterations later you have the finished piece!
Lower section where the sensor mounts
Upper section that mounts to the X-Axis carriage
Section analysis to check for clearance