Cable Spool from Prusa Spool Upcycling

With some additional parts you can make a perfect cable spool of a empty Prusament spool. It is made with bearings and rock solid. For example capable of holding 30m patch cable or what ever you like!

Print instructions

<!DOCTYPE HTML PUBLIC "-//W3C//DTD HTML 4.0 Transitional//EN">

<!-- @page { margin: 2cm } P { margin-bottom: 0.21cm } H1 { margin-bottom: 0.21cm } H1.western { font-family: "Arial", sans-serif; font-size: 16pt } H1.cjk { font-family: "Microsoft YaHei"; font-size: 16pt } H1.ctl { font-family: "Arial Unicode MS"; font-size: 16pt } H4 { margin-bottom: 0.21cm } H4.western { font-family: "Arial", sans-serif; font-size: 11pt; font-style: italic } H4.cjk { font-family: "Microsoft YaHei"; font-size: 11pt; font-style: italic } H4.ctl { font-family: "Arial Unicode MS"; font-size: 11pt; font-style: italic } A:link { so-language: zxx } --> 

Printing

I propose printing with a 0.6mm nozzle. Beacause of print speed. The print is tested with this values:

Material – Prusament Prusa Orange

Nozzle 0.6mm

First layer 0.25mm, Layer hight 0.25mm

Middle Part, End Pieces and Angles,: 4 perimeters, brim, 20% infill

Conus: 3 perimeters, 15% infill no brim

Crank Grip and Back: 2 perimeters, 15% infill no brim

BOM - Bill of material

Printed Parts

1x Middle Part

3x Angle

3x Endpiece

1x Crank Grip

1x Crank Back

Metall parts:

1x Threaded Rod M8 x 130mm

1x Drive in nut M8 ISO 6930, 11mm height

2x Nut M8 DIN 934

1x Cap Nut DIN 1587 or a normal nut and some screw glue

1x Spacer M8 DIN 9021

1x Screw M3 x 15 or 3,5mm Chipboard Screw

2x Bearing 608 2RS (8x22x7 mm)

1x Aluminium Tube 8mm x 130mm (Middle part to handle)

2x Aluminium Tube 8mm x 120mm (Middle part to foot angle)

2x Aluminium Tube 8mm x 90mm (foot angle to foot end)

1x Aluminium Tube 8mm x 70mm (handle)

13x Screw M3 x 10 or 3,5mm Chipboard Screw

Assembly Instructions:

Follow simply the pictures. The numbers of the pictures give the order of assembly. I have also written comments for most of the steps:

Cable_Spool_Instructions_02

You can cut the aluminium tube with a tube cutter

Cable_Spool_Instructions_08 and Cable_Spool_Instructions_09

Place the Crank Back. The plate only fit at some place!

Cable_Spool_Instructions_10 and Cable_Spool_Instructions_11

Remove one side of the filament spool and use the Crank Back as a stencil for drilling. Drill a hole depending on your screw. Something between 3mm and 4mm is possible

Cable_Spool_Instructions_16

Align the printed parts and drill a hole through one half of the tube

Cable_Spool_Instructions_17

Fix all tubes with screws. Save the End Pieces for the next step. Take the screw you like. M3 x 10 and drill a thread in the tubes or quick and dirty some 3,5mm – 4mm Chipboard screws. Chipboard screws are harded and they cut easy an alumium tube

Cable_Spool_Instructions_18

Align the End Piece

Cable_Spool_Instructions_23

Assemble the handle like the feet. Adjust the handle and drill the hole for the screws.

Cable_Spool_Instructions_26

Place the drive-in nut over the openings

Cable_Spool_Instructions_27

Place the threaded rod in the drive-in nut. Put first the plate on the rod and then two nuts on the other side of the rod. The turn both nuts against each other.

Cable_Spool_Instructions_28 and Cable_Spool_Instructions_28

Now you are able to drive the drive-in nut in the middle part.

Cable_Spool_Instructions_30

Losen the two nuts and leave one nut on the rod.

Cable_Spool_Instructions_31

Adjust the rod and tighten the remaining nut a little.

Cable_Spool_Instructions_31 and Cable_Spool_Instructions_33

Place the second nut on driv-in nut side and tighten the system now.

Cable_Spool_Instructions_34 and Cable_Spool_Instructions_35

Place the bearing and then the assembly on the threaded rod

Cable_Spool_Instructions_36

Place the Prusament Spool on the Conus

Cable_Spool_Instructions_40

Fix the spool with the second Conus

Cable_Spool_Instructions_41

… and the second bearing goes into place

Cable_Spool_Instructions_42

Fix the the system with a cap nut

Cable_Spool_Instructions_43

May you need a hole for one end of the cable

Cable_Spool_Instructions_46

Finish !