Started on the Y-Axis E-chain earlier today. I've got a length of chunky alu L-section that I rescued from my Dad's shed a while back and it's pretty much the ideal size for this job - well, maybe a little on the heavier-duty side...

First job was to drill and tap a hole on one of the plates that makes up the side to side moving part of the Z-Axis. Rather than take the whole thing apart, I used the plate edge tapping kit I 'designed' and had made by Dominic when I first joined the forum. Worked nicely...

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Then I machined a little (0.6mm) step into the L-section, this'll prevent it from slipping/rotating without having to use two bolts.

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I attached one end of the E-chain - looks alright so far. Space at a premium at this end of the axis as I need to get a little bracket in there somewhere for the limit switch...

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Next I need to make a 7mm spacer that will sit between the L bracket and the extrusion at the other end of the axis. Should look something like this:

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Again, recesses and proud bits are to prevent it (and the L-section) from rotating once bolted on.

There'll be another bit of L-section positioned somewhere in the middle to prevent the chain from sagging...

Wal.