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Heavy Duty 2040/4040 Extrusion Bracket
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Over 8"/200mm long bracket for joining 2040 and dual-slot 4040 extrusions.
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About
I had a heavy kitchen tabletop I wanted to salvage as a printer table. I used dual-slot 4040 extrusions but the brackets were not strong enough. This is the solution.
These joining brackets are ~240mm long. They must be printed in ABS or another suitably rigid and strong plastic.
Bill of Materials
- Printer enclosure that is stable above 40C
- 150g+ of ABS
- 8x M5 x 16mm socket head cap screws
- 8x M5 lock washers
- 8x M5 tee nuts
Printing Instructions
Rotate the model 45 degrees if you are printing on a 220x220 build plate.
- Material: ABS/ASA
- Enclosure temp: 45C with unmodified ABS
- Walls: 2mm
- Infill: 30% or higher
- Adhesion: brim and adhesive
- Layer height: 65-75% of nozzle diameter*
* This is 0.25ish to 0.32ish for an 0.4mm nozzle. Thicker layers improve strength.
Installation Tips
- Lock washers are not strictly necessary, but strongly recommended
- Use roll-in tee nuts instead of drop in.
- If you have any warp in your print near the edges, the screw holes closest to the warping will be unusable. This is okay if you still have 3 usable screw holes per side.
- Carefully check the angle and flushness of the bracket during installation.