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End caps for 20, 30, 40 and 10-series extrusion (1, 2 and 4 cells)

Name: End caps for 20, 30, 40 and 10-series extrusion (1, 2 and 4 cells) dimension sheet
Creator: Xem Studio
License: https://creativecommons.org/licenses/by/4.0/

What size end cap for 2020 extrusion? · Hardware · basis: Cap = profile outline (exact), 3 thick; pins = profile centre bore (exact) × 8 long, one per cell

Long Earth Society build part. Brackets and feet on the LES 2020 test stands; motor and bearing mounts hang off these. The engines

Exact dimensions. Every file is drawn at true size with no printing tolerance. The holes and pins that meet another part are listed below under Mating features, with the fit each joint needs; open those by your printer's or process's clearance before making the part. Mating features

sizes: 6 in table

Notes

Each cap is a 3 mm plate at the exact profile outline with R1.5 corners and one pin per cell, the profile's centre-bore diameter by 8 mm long with a 0.8 mm chamfer; 11 mm overall.
Pins: Ø4.2 on 20-series, Ø6.8 on 30 and 40, Ø5.1 on 10-series.
Sizes: 20-series 1 × 1 (20 × 20), 2 × 1 (40 × 20), 4 × 1 (80 × 20); 30-series 30 × 30; 40-series 40 × 40; 10-series 25.4 × 25.4.
The pins press into the centre bores (press, see Mating features).

Sizes

file	outline_mm	pins	pin_dia_mm
end-cap-20-1x1	20 × 20	1	4.2
end-cap-20-2x1	40 × 20	2	4.2
end-cap-20-4x1	80 × 20	4	4.2
end-cap-30-1x1	30 × 30	1	6.8
end-cap-40-1x1	40 × 40	1	6.8
end-cap-10in-1x1	25.4 × 25.4	1	5.1

Mating features

Drawn at the exact size. Open press, slide, run and socket features by your process's clearance; leave designed gaps and clamp fits as drawn.

feature	exact	mates with	fit	files
bracket / gusset / plate screw holes	Ø5.5 / 6.6 / 9.0 / 7.14	M5 / M6 / M8 / 1/4-20 clearance	designed	all
end-cap pins	centre bore (4.2 / 6.8 / 5.1)	profile centre bore	press	end-cap-*
end-cap outline	profile outline	profile end face	designed	end-cap-*

Where the files are

Other publishers' files are linked, not hosted. "verify" = check the license at the link before commercial use.

Wikipedia	T-slot nut	web	CC BY-SA 4.0 (text)
OpenBuilds	Tee nuts and brackets for V-slot	web, STEP	OpenBuilds site verify
Long Earth Society	Engine and rig builds on extrusion frames	web, video	LES site

Free files

★ Free files 6 parts. Generated by Xem Studio from the standard; threads are plain cylinders at major diameter. CC BY 4.0. index.json

end-cap-20-1x1	20-series end cap, 1 × 1 cells, pins Ø4.2 (the centre bore, exact) press into the bores	STEP · STL
end-cap-20-2x1	20-series end cap, 2 × 1 cells, pins Ø4.2 (the centre bore, exact) press into the bores	STEP · STL
end-cap-20-4x1	20-series end cap, 4 × 1 cells, pins Ø4.2 (the centre bore, exact) press into the bores	STEP · STL
end-cap-30-1x1	30-series end cap, 1 × 1 cells, pins Ø6.8 (the centre bore, exact) press into the bores	STEP · STL
end-cap-40-1x1	40-series end cap, 1 × 1 cells, pins Ø6.8 (the centre bore, exact) press into the bores	STEP · STL
end-cap-10in-1x1	10in-series end cap, 1 × 1 cells, pins Ø5.1 (the centre bore, exact) press into the bores	STEP · STL

Plain text: sheet.txt · JSON: /api/geometry?object=t-slot-end-caps

End caps for 20, 30, 40 and 10-series extrusion (1, 2 and 4 cells), isometric render of a generated part — Render of end-cap-20-1x1 from the free STEP; not to scale.

How it fits

Questions

What size pin for a 2020 end cap?

Ø4.2, the profile's centre bore, 8 mm long.

Is there a cap for 2040 and 2080?

Yes: end-cap-20-2x1 (40 × 20) and end-cap-20-4x1 (80 × 20).