Mark 4 build - step 6: Synchromesh

This step is fairly easy - attaching synchromesh cable to the rail effectors.

Vitamins:

• 3  * Synchromesh pulley
• 3  * 3mm grub screw (comes with pulley) 
• 3  * 2 meter length of Synchromesh cable
• 6  * 20mm long 1/8th inch heat shrink

RepRapped Parts :

• Everything you built so far!
• Idler guide (idler_guide.stl)

Tools : 

• 1.5mm hex key
• lighter  (or a heat gun if you have one)

Assembly:

1. Install the idler guide if you haven't already.
1. Pop out the bearing
2. Press the bearing all the way into the idler guide
3. reassemble
2. Loosen the idler slider - it should be as loose as it goes without falling out.
3. Attach the pulleys to the motor shaft with the grub screws.
1. Be sure to use the flat on the shaft, if your motor has flats.
2. You might want to grind a flat if you don't have one.  Slipping pulleys sucks.
4. Loop!
1. Slide the heat shrink onto one end of the synchromesh.
2. Form a loop, and then slide the loop end into the heat shrink as well.
3. You want about a small loop, but big enough to easily slide onto a 5mm bolt.
4. Make sure the synchromesh is doubled up for the entire length of the heat shrink.
5. Shrink!
1. The loop should be rigid, with the synchromesh locking against itself.
5. Slide the loop onto the lower bolt of one of your rail effectors.
6. Route the synchromesh onto the pulley, keeping it taught.
7. Route the syncromesh up and around the idler, keeping it taught and not twisting anything.
8. Finally, form another loop around the top peg
1. It doesn't need to be too tight.
9. Tighten the idler slider until the synchromesh is tight.
1. When plucked, it should vibrate to a low note.
2. Do not overtighten, you'll irritate your motor.