Rock Tumbler - Heavy Duty & Adjustable

I recently began dating a girl who is into rock tumbling, and decided to design her a heavy duty one to replace the National Geographic tumbler of hers that's falling apart.

This should accept two of the standard size tumbler drums while being adjustable enough to accept a single, much larger 15# drum - and everything in between.  Not all of the models are perfect, there were tweaks made during prototyping and I didn't originally intend to release this;  Please let me know if there are any that give issues with your slicer and I'll fix/update as I can.  

This is an extensive project that will require a few different skills/tools, I will outline the details below.  It will require ~100 hours of printing, ~1kg PETG filament, ~150g TPU filament, and will cost $130 in total based on the parts I used.  There are similarly priced ones available pre-made, but none with the adjustability or features that I wanted.  Most of the parts were designed to be printed with no support, though a few will require them.

Hardware Required:
M5 x 8 - x 85
M5 T-Nut x 81
M5 x 12 - x 4 (tensioner bracket)
M5 x 20 - x 1 (tensioner)
608 Bearing - x 2 (tensioner roller)
10mm Pillow Block - x 4
10mm 400mm Rod - x 1 (Front Roller)
10mm 350mm Rod - x 1 (Rear Roller)
8mm 20mm Rod - x 1 (Tensioner)
M5 Heat Press Insert - x 5 (L Cover Mounts)
M5 Lock nut - x 1 (Tensioner)
M3 Heat Press Insert - x 2 (Motor Bracket)
M3 x 12 - x2 (Motor Bracket)
M3 x 5 - x3 (Front Motor Bracket)

All Hardware was purchased through www.Zyltech.com 
 

Drive Components:
40mm D 8mm Pulley for 6mm Belt - https://a.co/d/1uIIbxY 
40mm D 10mm Pulley for 6mm Belt - https://a.co/d/9tT7RAr 
6mm Drive Belt - https://a.co/d/1DneJwa 
 

Electronics:
24v Power Supply - https://a.co/d/imvxEw3 
Switch - 16mm mounting hole - https://a.co/d/4NehuPe 
Motor - 421 RPM - https://www.aliexpress.us/item/3256805241838296.html 
PWM Controller - https://www.aliexpress.us/item/3256804118041379.html
24V 40x10mm Fan - https://a.co/d/1TGe9vQ 
 

2020 Extrusion:
400mm x 2
250mm x 2
190mm x 2
150mm x 2
90mm x 2

 

The design allows for all wiring to be run through the extrusion, the routing of which I'll let you decide.  I'm choosing to attach the fan (JST-XH) with a matching female connector for ease of replacement.  Belt tensioner should have a fair amount of adjustment but will likely require a different belt length for either extreme.  I'll update this post with additional notes and pictures as I complete my build.  If there are any part design changes I will update the .zip and the additional files.  

4/23/24 - I realized ChatGPT's math was a bit off for the size tumbler I was going to use.  I've edited the post and files to reflect the changes.  The max RPM of a 100mm diameter drum should be 125RPM now.

4/24/24 - Updated spacing for the pillow block bearings on L_Cover_Out and R_Cover_Out.  Gave Power_Cover some additional clearance and modified R_Cover_In for a better fit.  

5/10/24 - Added [rear] roller guides for multiple barrels & a shim for each.  Also added a more visually appealing front cover (v2)