A while ago I came up with a design for a new X axis for a Vertical configuration (vX config) based on bar spacing of 70mm for the vertical spacing and 30mm between the Z axis lead screw and smooth rod, per the original Reprap Mendel spec. Long story short, my printer is running great now after some time of neglect and I've been able to work on this design more and iron out some potential kinks!

The key difference now is that in addition to a Vertical configuration, I've come up with a Horizontal configuration (hX config) which uses the same zClamps, so if you're perfectly happy with your carriage and extruder, but want to try new Z ends this should offer an alternative to the default Mendel setup.

As for the vX config, it's untested in the sense that I don't have a working setup with this implementation but I will eventually. For now I have printed all parts except the main motor bracket and all prints have gone well and Slicr is doing a good job bridging the overhangs without using support.

Currently I'm testing out the Horizontal configuration and will update with any notes.

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Just for the sake of clarity, the Configurations break down like this:

vX Config

• zClamp_4off
• vX_motorBracket_1off
• vX_barClamp_4off

hX Config

• zClamp 4off
• hX_motorBracketA_1off
• hX_motorBracketB_1off
• hX_endBracketA_1off
• hX_endBracketB_1off
• hX_barClamp_4off

Materials
I'll fill this out once I have a proper list of the bolts needed but for now, experienced modders should be able to piece it together in the mean time :)

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Z Clamp Assembly (universal):

1. Install linear bearings and M8 nut on Z axis rods
2. Align linear bearings and M8 nut with one half of Z clamp and close with other half of the Z clamp
3. Insert M4 bolt into center hole with 2 M4 washers and nut (if assembling vX config, install motor bracket first, then fasteners)

vX Assembly:

1. Install vX_motorBracket when installing left side zClamps using M4 bolt, M4 washers and nut
2. Insert M4 bolt withM4 washer into a remaining hole, then place vX_barClamp, M4 washer, small bearing, M4 washer, M5 Mud washer and finally an M4 nut but leave them loose
3. Repeat for each remaining corner
4. Insert X axis smooth rods into clamps and tighten down all corners

hX Assembly:

1. Place endBrackets A and B on the correct sides of the installed Z clamp assembly and fit M4 bolt with 2 M4 washers and a nut
2. Install small bearings on endBracketA and B with 3 M4 washers, M5 Mud Washer and nut each
3. Repeat Steps 1 and 2 for motorBracketA and B, as well as bearings.
4. Install motor to motorBrackets using M3 bolts

Notes:

• before tightening down the X axis smooth rod clamps for either config, it's probably a good idea to slide your X carriage all the way to that side, tighten clamps then slide to the other side and tighten the other clamps

For now I'll be focusing on the hX config because I want to make my own extruder/carriage for the vX config based on Gregg's Accessible extruder, or something close to that, so in the mean time I'll make sure the hX works well before moving onto the vX, but it should work fine.

Be sure to leave a comment with any questions or suggestions!