Xtool D1 X carriage replacement complete with fittings for Lasertree K30 module

I found that the design of the original X carriage on the Xtool D1 printer made it really difficult to remove slack - the adjustment being by  nut and bolt and squeezing the bottom deep groove bearing against the rail…the adjustment inevitable moved when being tightened.

This model replaces the original single piece X carriage with an upper and lower groove bearing holder.  The two  are connected via 3 printed guides and have a max of approx 3mm gap between them.  Two M3 hex head bolts then tighten the two parts together until all slack is removed; a very quick and reliable process, with easy access from above.  

I have a Lasertree K30 so the design includes the 3 mounting points for the K30 backplate. The STEP files can be modified to suit any other laser module.

I printed in ABS with 3 walls and 25% infill as the general setting but then used modifiers in the slicer to print the top unit at 5 walls and 60% infill.  I also used modifiers to increase the walls to 5 around all threaded insert positions.

UPDATE - Ive added STEP and STL files for a version that uses standard M3 and M5 nuts rather than heated thread inserts.  By necessity this model is larger and I have not printed it but the nut clearances are to standard spec

Threaded insert version :Hardware needed:

2 x M3 x 6mm threaded inserts (and a means to insert them - for ABS I use a solder iron with threaded insert adaptor and 220c)

3 x M5 x10 threaded inserts for the bearing holder.s I reused the original bearings and shoulder bolts.

2 x M3 x 20mm hex head bolts

3 x M5 x 8mm button head bolts if fitting a K30 plate.

The belt holder is fitted using the original screws.

Standard nut version: Hardware needed

2 x M3 nuts

3 x M5 nuts

2 x M3 x 25mm hex head bolts (longer due to position of nut)

3 x M5 x 8mm button head bolts if fitting a K30 plate.

The belt holder is fitted using the original screws.

Assembly:

1 - insert all the heated inserts flush / insert nuts

2 - fit the bearings and belt holder

3 - fit the K30 backplate (this attaches only to the lower roller frame)

4 - align the top frame to the bottom and just catch the threads on the M3 bolts

5.- You should have enough slack to be able to fit this assembly to the X frame. Once fitted just evenly tighten the two M3 bolts until there is no forward/back slack and the rollers run smoothly.  Don't overtighten.

6. Reattach the belt 

7. Attach the laser module and recheck there is no slack - if so remove by slightly tightening the M3 bolts.