INTRODUCTION

I have recently built a FormBot Voron V0.2 printer and found that the printed strain relief spacers are not only difficult to put heatset inserts in without them going out of shape but they are also very weak. Because of this I started to design replacements that are not only sturdier but actually look good. I have gone through a good 5 prototypes of both the strain relief spacer and the toolhead cover so a lot work has gone into this one. Hope you like it!

THE DESIGN

To design this and make it sturdier, I had to change the shape of the strain relief spacer and make it fit against the stealthburner mini's surface. This provides the part great strength and support. The initial design was a 2 piece that wraps around the pancake stepper motor but leaves the top exposed (will include this in the STL's). This then evolved to covering the top and flipping the motor so that the wires face downwards. The top of the mount is closed but there are side air vents. Did a few days of testing to ensure that there are no issues here. 

CAUTION: Ensure that the right current is set for your motor as this will make your stepper motor run hotter than it should. I will not be held responsible for issues should the stepper motor overheat.

Next I worked on the toolhead cover as I really did not like the wiring left exposed. Again I went through multiple versions of this to get it to where I feel it fits and looks best. There are 2 versions below depending on how you prefer the part to fit.

The parts are already oriented in what I think is the best position to print them in. The strain relief spaces can be printed without supports but the toolhead cover will need supports to be enabled. It is recommended to print this in either ABS or ASA since this will be in an enclosed chamber.

BOM

This upgrade requires minimal parts and uses back some of the screws. You will need the following: -

1. 2 x M3x10 BHCS (original parts) to screw the stepper motor and strain relief spacer part toghether.
2. 4 x M3 heatset inserts (original parts) you should have some spares from the kit.
3. 2 x M3x8 BHCS to hold on the toolhead cover. These replace the original M3x6 BHCS screws.

LEGEND

There are several versions of the parts so please take note of the differences described below

• FT Strain_Relief_Spacers V1 - 2 peice strain relief spacer with the top of the stepper exposed.
• FT Strain_Relief_Spacers V2 - 1 piece strain relief space that will require you to rotate the stepper motor 180 degrees so that the wires are facing down. This is tested fotr moons motors.
• FT Strain_Relief_Spacers V3 - 1 piece strain relief space that will require you to rotate the stepper motor 180 degrees so that the wires are facing down. This was modified for the LDO stepper as the mount on the stepper is thicker.

INSTALLATION INSTRUCTIONS

1. Download and print the parts you would like to use for your upgrade.
2. Insert the 4 x heatset inserts into the strain relief spacer you chose to download.
3. Single piece strain relief spacer
   1. Unscrew the stepper motor from the Stealthburner mini. Take note of the position that works for you on the adjustable side - you will need to match this later when assembling.
   2. Flip the stepper motor 180 degrees so that the wires are facing downwards.
   3. Hold the fixed hole side of the motor and the strain relief in place and screw the M3x10 screw through the Stealthburner mini → stepper motor → strain relief spacer. Ensure that all 3 are flush as you screw them together. Do not tighten until the adjustable side is secured.
   4. On the adjustable side of the Stealthburner mini, hold the stepper and strain relief space in place in accordance to the position you observed in step 3.1. Hold the 3 parts flush together and screw them together using the M3x10 screw.
4. 2 piece strain relief spacer
   1. Unscrew the stepper motor from the Stealthbrner mini. Take note of the position that works for you on the adjustable side - you will need to match this later when assembling.
   2. Hold the fixed hole side of the motor and the strain relief in place and screw the M3x10 screw through the Stealthburner mini → stepper motor → strain relief spacer. Ensure that all 3 are flush as you screw them together. Do not tighten until the adjustable side is secured.
   3. On the adjustable side of the Stealthburner mini, hold the stepper and strain relief space in place in accordance to the position you observed in step 3.1. Hold the 3 parts flush together and screw them together using the M3x10 screw.
5. Manually turn the 50T gear and ensure that it moves smoothly. You may need to use a small screwdriver to push the teeth but be gentle. If the gear is too tight then the adjustable screw side will need to be checked and adjusted.
6. Mount the Stealthburner mini back to the printer using the 2 x M3x35 BHCS screws in the front and the M3x16 BHCS screw from the rear (its advisable to do this step before attaching the toolhead cover if you are planning to use the longer version. For the shorter version the rear screw will still be accessible. 
7. Mount the toolhead cover using the M3x8 BHCS screw ensuring that all wires are not sticking out.
8. Connect up the 14 pin cable and use a zip-tie to secure it to the strain relief.
9. ENJOY!

If you like my designs and would like to contribute to fund filaments and other equipment required for prototyping, please do so at my paypal.me or Ko-fi. Your support is greatly appreciated :) 

CHANGE LOG

12-June-23

1. Removed FT Toolhead_Cover V1 as it causes issues with the sensorless homing because it does not allow the Stealthburner Mini to go to the end of the Y rail. Problem only became obvious once I tried to print using the full bed.
2. Updated design uploaded as FT Toolhead_Cover V1-1 - This has a shorter back that does not collide with the A/B Drive mounts.