Lasersaur replacement idler pulley bracket

by Zarquon, published

Lasersaur replacement idler pulley bracket by Zarquon Sep 6, 2012



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I don't see any one else needing to make this but in the spirit of open source hardware I'm documenting the replacement part.

A friend of mine is building a lasersaur (http://labs.nortd.com/lasersaur/ ). The original design for this bracket calls for 2 sheets of 6mm plastic to be laser cut. Being in the US we used what was readily available and approximated the thickness with 5 sheets of 1/8 in. Everywhere else in the design the approximated thickness plates worked out fine. At this location there was enough inaccuracy in the thickness that the sleeve for the pulleys bearings torqued out a bit under the belt tension. With the pulley sitting at an angle to the belts path the teeth were catching causing uneven feeding and the wobbly path pictured.

This pieces is a replacement for the original bracket. It fits very tight and well need to be press fit while using a heatgun to get the bearing sleeve in.

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Oh yeah, and I can't wait for the lasersaur open source release!

As of this fix and the most recent round of software updates the lasersaur has surpassed our 10ish year old used commercial laser cutter in reliability. It was an important milestone for us. The build was a bit more complex then a reprap but that's probably due to early stage documentation and design. I've been happy with how its going but the friend I'm working with doesn't seem to be as happy. He's an artist not an engineer and he couldn
’t have got it running himself.

Acetone also does a good job for bearing-insertion tasks. Just brush some around inside the bearing housing, let it sit for 30 seconds or so, and squish your bearing right in. Obviously, don't load it up until it hardens again 8]

As my parts ware printed out of PLA I have to use a heat gun instead of acetone.