Voron Stealthburner — Phaetus Rapido X Toolhead Mount & Duct (Fixed Geometry & Max Z-Height)

Overview

The official Phaetus Rapido X mount model contains critical geometry flaws (cable outlets intersect mounting screw holes, and the provided STEP files are corrupted or improperly modeled).

This project is a completely redesigned and optimized Phaetus Rapido X mount and part-cooling duct for the Voron Stealthburner, built from the ground up using official Voron Design CAD source files.

Key Features & Improvements

1. Maximized Z-Height (Shifted Upwards):

   • The hotend mount was shifted as high as possible inside the body to minimize Z-axis travel loss.

   • Hardware Note: Due to the higher seating position, the stock screws provided in the Rapido X kit are too long. Replace them with M3×6 mm screws.

2. Redesigned & Extended Part Cooling Ducts:

   • Part cooling air ducts have been completely redesigned and lengthened to match the new nozzle position while strictly preserving all core dimensions and clearances of the original Voron Stealthburner design.

3. Enlarged Heat Sink Cooling Vent:

   • Because the hotend sits deeper inside the toolhead, the heat sink cooling vent was enlarged to ensure proper, unobstructed airflow across the heatsink.

4. Repositioned Toolhead Body Mounting Holes:

   • The width of the Rapido X body prevented it from fitting between the standard Stealthburner mounting posts. The two body assembly mounting holes were spaced further apart to clear the hotend while maintaining full structural integrity.

5. Adapted Hotend Mounting Geometry:

   • Mounting holes and internal seating geometry were custom-adapted to fit the Rapido X mounting pattern precisely.

6. Stealthburner Front Cover Compatibility:

   • The air duct extends slightly beyond the standard Stealthburner main cover contour, but it remains 100% mechanically compatible with the stock front cover without requiring any modifications.

Bill of Materials (BOM)

• Screws: M3×6 mm (button head / socket head) — 4× for securing the hotend into the mount.

• Threaded Inserts: M3×5×4 mm — 2× heat-set inserts (standard Voron spec).

Recommended Print Settings

Follow official Voron Design guidelines:

• Material: ABS or ASA (mandatory due to thermal exposure).

• Layer Height: 0.2 mm.

• Wall Count / Perimeters: 4.

• Top / Bottom Layers: 5.

• Infill: 40% (Grid / Gyroid).

• Supports: Standard Voron orientation no supports required ).