COMPLETE Production spool updgrade "upgraded"

Discussion in 'Guides, Mods, and Upgrades' started by Alex9779, Apr 20, 2016.

  1. Alex9779

    Alex9779 Moderator
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    I bought some 2.2kg spools Colorfabb XT.
    To use them on the spool holders of the BigBox you have to change some parts a bit.

    In the file repository in the folder "STLs" is a "production" folder with a file "rear_cable_bracket_for_production_spools_x2.stl".
    This is a vertical cable guide for the back side replacing the two middle spine parts so the production spools have enough space:
    Spine comparison.PNG IMG_0566.JPG
    The upper one is normal, lower is the production one. I altered it a bit and added some fillets so it prints a bit better.

    But when I mounted that parts and placed the spool on the holder I realized that I had another issue:
    IMG_0567.JPG
    As you might be able to see on the image the spool is very close to the back of the BigBox. If you look at the spool holders you see that the bearings are touching the back and with the two bearings you have about 9.5mm surface for the spool to rest on.
    And as you can see on the picture the spool is huge and there are ribs on the side.
    And this is the issue. I was not able to rotate the spool freely because two screws, on the image you see the upper one, scratch the spool and because of the ribs the spool hangs and makes a loud noise when rotating.

    Unfortunately because the bearings are small and directly touching the back you cannot move the spool more away from the back.

    So I designed a spacer based on the shape of the inner spool holder:
    Spool Holder Inner Spacer.PNG
    This part fits between the back and the stock spool holder and moves the bearings 7mm away from the back:
    IMG_0568.JPG
    It is also a little bigger on the upper side so the spool cannot slip over the bearings.

    To mount those I unfortunately had to open the bottom plate...
    And you need longer screws. Instead of the M3x20 I used M3x30.

    This is the result:
    IMG_0569.JPG
    The spool is now guided between the spool holders and not by the back of the box and away from the screws.

    It remains the spool holder clamp.
    I also designed a replacement part for this because after that mod the clamp is a little to short to reliably fix the spool in the middle:
    Spool Holder Clamp.PNG IMG_0573.JPG
    This is basically the stock part but longer by 10mm.
    To mount this you need a M4x40 screw instead of the stock M4x30.

    (Can't post a picture because I didn't have M4x40 screw, ordered some, maybe tomorrow they will arrive, then I can show).
     

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    #1 Alex9779, Apr 20, 2016
    Last edited: Apr 23, 2016
    Colin, Greg Holloway, Stefan and 4 others like this.
  2. Ephemeris

    Ephemeris Well-Known Member

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    Very nice. I'd been thinking about this problem and here you've already solved it!
     
  3. R Design

    R Design Well-Known Member

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    Nice job.

    I've been getting by, adjusting my big 2.2kg spool on the back so it balances just right and doesn't touch.

    What you've done is an excellent idea.
     
  4. Alex9779

    Alex9779 Moderator
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    Thank you!

    It it also good for standard spools.
    I used a black spool and it left some stripes on the case because it was constantly rubbing it...

    So it could be an upgrade for everyone except the changed spine parts...
     
  5. Spoon Unit

    Spoon Unit Well-Known Member

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    As I'll be rebuilding during Titan fitting, I'll be adding this upgrade. Thanks @Alex9779 !

    Actually, where are the designs? :)
     
  6. Alex9779

    Alex9779 Moderator
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    Here they are. (Added to the first post.)
    I do not wanna create Thingiverse things because I do not know which License I have to select for the modded part...
     
  7. Spoon Unit

    Spoon Unit Well-Known Member

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    Thanks @Alex9779 . They're going straight on to print. 4 outers and 2 inners. I suppose this will slightly increase the turning moment from the weight of the spool.
     
  8. Alex9779

    Alex9779 Moderator
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    Errr no... You need 4 spacers (SPOOL-HOLDER INNER spacer) and 2 clamps (SPOOL-HOLDER CLAMP OUTER_longer)...
     
  9. Spoon Unit

    Spoon Unit Well-Known Member

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    That's what I printed, meant, and failed to say :). Thanks for double checking.
     
  10. Alex9779

    Alex9779 Moderator
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    Finally got the longer M4 screws, pic in the first post...
     
  11. Spoon Unit

    Spoon Unit Well-Known Member

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    Need to find a good way to source a bunch of these screws I think. Buying in tiny numbers seems to be about the most expensive option.
     
  12. Alex9779

    Alex9779 Moderator
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    I ordered 100 for 7,90€...
    I have 98 left. You need some? :p
     
  13. Spoon Unit

    Spoon Unit Well-Known Member

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  14. mike01hu

    mike01hu Well-Known Member

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    Kay's Fasteners on Ebay do small numbers for UK delivery FOC. A great source for stainless screws, nuts and washers.
     
    Spoon Unit likes this.
  15. Spoon Unit

    Spoon Unit Well-Known Member

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    @mike01hu thankyou. That seems a more reasonable price.
     

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