Small filament spool (⌀200 mm/ 40mm) - upcycling Prusa / 3dimensional spool

Spools of 3dimensional and Prusa seems to be identical. I have upcycled a 3dimensional spool (⌀200x76).

Cut the spool in the middle. To get a constant thickness of the spool, I recommend to use a piece of wood which fits to the inner of the spool to guide the saw blade (see picture).

1. Make a cut in the middle of the piece of wood 
2. Clamp the spool in a vice.
3. Use a frame saw and put the piece of wood to the rear side of the saw blade.
4. Cut the spool.
5. In the next step cut off the cylinder of one the two parts. To avoid scratches in the plastic part, mask the saw blade with tape where you do not cut.
6. Remove burr and clean the parts from chips.
7. Put both spool parts and clamping parts together, allign the parts and drill bores ⌀3mm (4x).
8. Remove burr and clean the parts from chips.
9. Assemble the small spool using hexagon nuts M3 (4x) and cylinder screws M3x16 (4x).

To spool rest of filament to your new small spool, you could use my suitable spool winder.

Link: Spool winder for spools with bore Ø38mm up to Ø64mm von H3dSprint | Kostenloses STL-Modell herunterladen | Printables.com