Tevo Tornado Direct Drive adapter plate for stock hotend and dual gear metal extruder

Description

I printed s_gutz's CR-10 Direct Drive adapter plate, but on my Tevo Tornado with my upgraded dual gear extruder, I realized that the left side stuck out too far and prevented the carriage from touching the Z endstop, so it would just collide, and the motor mount was 10mm too far forward to accommodate the extra thickness of my extruder. I'm using the generic aluminium body dual-gear extruder that was available in 2019 and 2020 from Winsinn, which I opted to use instead of a lower profile extruder because it's the only extruder I own that's suitable for printing soft and flexible filaments that might buckle (this one has the cutout to surround the extruder contact surfaces in the rounded inverted V shape). https://www.amazon.com/gp/product/B07SY745CF/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1 It's worth mentioning that mounting the motor in this orientation takes about 3cm of X travel off the total usable build area and about 6cm off the Z height, so if you need the full build volume this isn't the mount for you. You'll need to reconfigure your printer settings to account for this if you do any kind of mesh bed leveling with a sensor and any start/end scripts you have set up that specify X positions beyond X pos 270. With my build volume, I've got a zmax of 340 and an xmax of 272. You could probably squeeze out a little more z height with good cable routing. v1.1 rev.1 is installed on my carriage, and it works perfectly! This design calls for the following bolts not supplied with the printer or extruder: M3-12mm x 4 M3-25mm x 2 M3-30mm x 1 2 of the 12mm bolts are used to retain the bottom of the stepper motor to the mount, since the 8mm bolts that came with the extruder are too short. The flush screw is long enough to bite, so that one was fine, but the bolt to retain the tensioning arm was too short, so that one takes the 30mm bolt The other two 12mm bolts are for retaining the fan cage and my bltouch mount. There's a ton of space behind where these bolts screw in, so you can fudge it by +5mm or maybe even more if you need to. The bltouch mount I use only adds 1.5mm of thickness, so 12mm should be good whether you have one or not. I might see about integrating a BLtouch mount in another model if anyone asks for it, but I use the old version of this mount that I printed ages ago, and it fits just fine: https://www.thingiverse.com/thing:2667735 Either way, I'm including my FreeCAD work file with all my geometries and changes, so if you want to tweak anything without having to start completely over, have at it! Changelog: v0.1 Set motor plate rearward 10mm and added rigidity to the resulting connecting structure v0.2 Shortened left side of adapter plate to avoid collisions with frame. v1.0 increased tolerance for extruder bottom face at motor plate supports. Added extension to help the carriage actuate the Xmin endstop before the extruder motor collides with the frame. v1.1 Modeled a chamfer into the Xmin endstop extension to reduce filament usage and ease printing. v1.1 rev.1 Added cutout to ease access to extruder tensioning screw

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