Simax3D IronM1 X Axis Linear Rail Conversion

This is the culmination of projects while I've been printing parts to build a Voron. I decided it was time to convert the X axis to a linear rail. I combined this with my shroud design which will hold any E3D V6 compatible hotend.

The X Carriage design is blatantly inspired by the Voron Switchwire; it is my design from scratch, but you can see the inspiration clear as day. You will need to print both halves. You will also need the 2 E3D mount parts, as well as two of the belt holders.

Hardware wise, you will need: 

• 18 x M3x8mm SHCS 
• 3 x M3x45mm SHCS 
• 2 x M3x16mm SHCS 
• 3 x M3 nuts 
• 10 x M3 heat set inserts 4mm ~ 6mm 
• 4 x M5x8mm BHCS 
• 4 x M5 T nuts 
• 2 x M5x16mm BHCS 
• 2 x M5 nuts 
• 6 x M3 T nuts 
• 1 x 300mm MGN12H Linear Rail 
• ~650mm GT2 Belt. 
• 4 x F695 Bearings 
• 4 x 1mm M5 shim spacers.
• Zip ties.

Printed parts should be in ABS or PETG if you don't plan on printing ABS. 40% infill, 4 perimeters, 4 top and bottom layers.

• 1 x X_Carriage - Part 1 
• 1 x X_Carriage - Part 2 
• 1 x IronM1E3DMountShroudBase 
• 1 x IronM1E3DMountShroudTop 
• 2 x BeltHolder 
• 2 x F695_LowerMount

I've included a screenshot showing the plating of the parts for print orientation.

Most likely you will need to ream holes slightly. I left them a little on the tight side. I also recommend lightly sanding the mating surfaces of the E3D holder to ensure a snug closure.

For assembly, refer to the attached photos and the assembly model. It's pretty easy. The X carriage parts bolt together with the three 45mm bolts, and nuts. The nuts press fit into the one side of the carriage. Heat set inserts: 

• 4 in the front face of the X carriage.
• 2 in the belt holders.
• 4 in the shroud base on the front.

For the F695 mounts, press fit the M5 nut into the side of the part, the assembly order goes shim spacer, F695, F695 (oriented with the flanges on the outside), and finally shim spacer; run the M5x16 button head screw through everything. You can tighten this pretty good; don't crush the plastic, but make sure it's snug. These mount to either side of the extrusion on the bottom with the T-nuts. You may need to sand the X carriage lightly to clear these.

You will need to flip the X end stop to the front of the mount plate.

You will end up with the hotend about 8mm lower, and 20mm forward. You will need to reduce your Y bed size to 200 from 235. I am working on a Y axis rail conversion that will move the bed forward ~35mm to get that 235 back, but that's down the road.

This is specifically for the Simax3D Iron M1, but it would most likely adapt to darn near any printer that uses a 2020 v-rail extrusion for the X gantry, such as the Ender series.