[ddmckee54]

Two steps forward, one step sideways, and one step back.

I measured all of the internal pockets on the diff halves, they were ALL consistently about 97.4% of the model size. That's the size I would expect them to be when you allow for shrinkage. I'm beginning to wonder if my version of S3D scales internal dimensions? I really need to try scaling the slicer to about 150% and see what the pockets look like then as an experiment - without printing anything.

Anywho... I scaled the critical pocket dimensions to 103% in the model, the same as my scaling factor in S3D and printed the diff halves again - things are REAL close. The inner bearing pockets are a little bit too tight, and the outer bearing pockets are a little too loose. When I tighten all the screws holding the halves together the outer bearings will slip out of the pocket, and the inner bearings will not turn freely - but I think that's MY fault.

The outer bearing pocket dimension when scaled was 4.84mm and change, I just rounded it up to 4.85mm. The inner bearing pocket dimension when scaled was something like 6.12mm and change, I just rounded it down to 6.1mm. I'm going to print this one more time, but this time I'm going to round the pocket dimensions to the 3rd decimal place and see how that works.

Don