Gates Idler mounts for Rostock Max by tajd3

Last crawled date: 2 years, 11 months ago

I have a Rostock Max v2, but I think this should work for all versions with motors in the base, though I have not verified this. Check all dimensions of your model before you start this upgrade.
I was getting some vertical banding (NOT ringing) on my prints and decided to replace my belts and stock idlers with authentic Gates parts. Plus my original belts were getting pretty worn.
Because the Gates idlers are much smaller (12mm vs 22mm diameter) than the 608zz bearings used as the original idlers, new brackets are needed to maintain the proper belt alignment. These brackets improve the belt alignment over stock. On the outside, the belt path is within the extrusion V-track and on the inside the belt path is completely outside the extrusion V-track. The belt path with the stock idlers was right at the mouth of the inner and outer V-tracks which allowed the belt to rub on the ends of the extrusion causing friction and belt wear.
This design reuses all the original fasteners and holes in the tower supports.
The following hardware (in addition to the existing) is required for the base:
6 of 5mm X 20mm stainless shelf pins
12 of 5mm ID X 6mm OD X 0.4mm shims
12 of M5 washers
3 of Gates GT2 20T idlers
3 of Gates GT2 smooth idlers
3 of Gates GT2 16T pulleys (optional - gives an increase in resolution from 80steps/mm to 100steps/mm)
3 of M4 x 45mm screw with lock nuts and washers (12 washers total)
The following hardware (in addition to the existing) is required for the top:
9 of 5mm X 20mm pins
12 of 5mm ID X 6mm OD X 0.4mm shims
12 of M5 washers
6 of Gates GT2 20T idlers
6 of 625zz bearings (optional - a printed part will work as well)
3 of M4 x 45mm screw with lock nuts and 4 washers each (axle for bearings above)
6 of M3 x 8mm screws (to adjust the position of bearing axle)
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