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In addition to the written assembly notes here, there is a series of assembly videos for this design on YouTube.
The instructions below are divided into 7 parts, which correspond to the order in which the video series is presented.
1.1 Lay one of the plastic Y ends flat on the table and insert the two extrusions and the two smooth rods into the holes provided. If the holes or slots are too snug, gently tap the extrusions/rods into place with a mallet or the flat of your palm, being careful to apply force straight down and not to twist the plastic which will cause it to break.
1.2 Insert 6 T-slot nuts into each of the extrusions: two each in the left, right, and top slots (the top is the side of the extrusion toward the smooth rods).
1.3 Slide two Y axis frame brackets over each of the extrusions, so that the pointy end of the brackets points down and the flat sides of each pair are toward each other.
1.4 Place two linear bearings over each smooth rod.
1.5 Place the remaining Y end over the extrusions and rods, and press down firmly until the extrusions are completely against the inside of the plastic part.
1.6 Secure the extrusions to the Y ends using 8 M5x10mm screws through the holes provided and into the T-slot nuts that are on the left/right sides of the extrusions.
1.7 Attach the Y axis frame brackets to the four T-slot nuts on the bottom edge of the extrusions using four more M5x10mm screws.
1.8 Prepare the MDF sheet as shown in the drawing. The Y-table should be centered left-to-right and placed about 80mm from the end toward the Y motor (the notched end). Place the Y-table and the heat bed each over the MDF sheet and mark the holes using a pencil. Predrill the 8 holes using a 3mm or 3/16” drill bit.
1.9 Mount the MDF sheet to the Y-table using M3x14mm screws and nuts. The screws should be inserted from the MDF side (the top) and then through the y-table.
1.10 Place the assembled MDF sheet and y-table over the smooth rods and align each linear bearing with one of the curved slots on the y-table. Secure with zip ties through the slots built into the y-table.
1.10 Mount the motor to the Y motor end using 4 M3x10mm screws and attach the pulley to the motor shaft.
1.11 Mount the prewired endstop to the Y motor end using 2 M2x16mm screws and M2 nuts. The lever arm should point up so that the edge of the MDF sheet strikes it when you slide it toward the Y motor end. Secure the wires from the endstop and the motor to the Y motor end using a zip tie through the small slot built into the plastic piece.
1.12 Snap the 624 bearing into the two piece bearing guide, then fasten to the Y belt tensioner using a M4x20mm screw and locknut. On the adjustment end of the tensioner, insert a M3 nut into the provided slot and thread in a M3x30mm screw until it is through the nut and a centimeter or so into the rectangular slot in the tensioner. Install the tensioner into the Y idler end with another M4x20mm screw and nut so that the bearing end faces inward. The end of the M3x30mm screw in the end of the tensioner should be touching the side of the M4x20mm screw that is holding the tensioner in place. (Tension is adjusted later by turning the screw in which pulls the tensioner outward).
1.13 Attach the GT2 timing belt.
2.1 Test how easily the two smooth rods slide into the holes on each X end. They should be snug but not so tight that you can't pull the rods back out with reasonable force. If they are too tight, use a 8mm or 5/16” drill to smooth and enlarge the holes before proceeding. This is important because the Z axis smooth rods (later) will need to be able to push/pull the X ends the correct distance apart from each other to prevent binding of the Z axis.
2.2 Press two linear bearings into each X end from the bottom. Press two more linear bearings into each side of the X carriage. If they are too tight to press in by hand, gently but firmly press the bearings in with a vise or C-clamp. Do not use a hammer to tap the bearings into place, as this will likely damage the bearings.
2.3 Snap the 624 bearing into the two piece bearing guide, then fasten to the X belt tensioner using a M4x20mm screw and locknut. On the adjustment end of the tensioner, insert a M3 nut into the provided slot and thread in a M3x30mm screw until it is through the nut and a centimeter or so into the rectangular slot in the tensioner. Install the tensioner into the X idler end with another M4x20mm screw and nut so that the bearing end sticks out the same side as the two rod guides (holes). The end of the M3x30mm screw in the end of the tensioner should be touching the side of the M4x20mm screw that is holding the tensioner in place. (Tension is adjusted later by turning the screw in which pulls the tensioner outward).
2.4 Insert a leadscrew nut into each X end. Insert through the side which faces toward the rods (the “down” side when the X axis is installed) and secure the nut with two M3x14mm screws and nuts (there are four holes, but only two screws are needed, it doesn't matter which two holes you use).
2.5 Insert a M3x30mm screw through the spring and then through the square slot on the back side of the X motor end. Thread the screw through a M3 hex nut which should fit into the hexagonal recess built into the bottom side of the X motor end.
2.6 Attach the stepper motor to the X motor end using four M3x14mm screws. Secure the pulley on the shaft of the stepper motor. The teeth of the pulley should line up with the slot through the center of the X motor end (this may require you to turn the pulley around).
2.7 Attach the endstop switch to the X motor end using two M2x16mm screws and M2 nuts. The screws should go in from the switch side, then through the plastic (so that the ends of the screws do not stick out in front of the round holes on the X motor end). Secure the wire for the endstop switch using a zip ties through the provided slots in the X motor end. The third zip tie slot, which is on the side of the part where the motor attaches, should be used to secure both the endstop wires and the stepper motor wires, to provide strain relief.
2.8 Insert the two smooth rods into one X end, then slide the X carriage onto the two rods, followed by the other X end. The “back” of the X ends is the flat side, and the X carriage should be installed so that the flat side is toward the front of the X axis, with the teeth of the belt guide on the back of the X carriage pointing up (see images below). Set the X axis aside for now – you'll install the timing belt later after it is installed on the upright frame.
4.1 Insert the 624 bearing into the idler piece and secure with a M4x20mm screw and nut.
4.2 Attach the stepper motor to the extruder body using three M3x30mm screws with washers. The lower outside corner should go through the idler part and hold it in place.
4.3 Place the drive gear over the shaft of the stepper motor and tighten the set screw(s) so that the teeth of the drive gear are centered over the hole through the extruder body.
4.4 Insert an M3 hex nut into each slot on the top side of the extruder body. For each M3x60mm screw, place a washer, then a spring, then another washer over the screw and then insert the screw into the oval slot on the idler and thread into one of the M3 hex nuts you installed in the extruder body. Tighten the two screws so that the springs are tight (do not overtighten, you should be able to pull the idler back with your thumb by applyig a few pounds of force). The idler bearing (624) should rest against the drive gear.
4.5 Attach the 40mm fan to the fan duct using four M3x14mm screws and hex nuts, keeping in mind which side of the fan is the “outlet” which goes toward the fan duct (this is usually the side of the fan with the manufacturer's label). Attach the fan duct to the extruder body using a M3x30mm screw and locknut.
4.6 To attach the hot end, put two M3x30mm screws through the hot end clamp, then push the hot end into place on the extruder (there is a groove which it should “snap” into) and attach the clamp to the outside, through the extruder, and secure with M3 hex nuts. Before tightening down the screws, rotate the hot end so that the heater and thermistor wires come off to the right side of the extruder (the same side as the motor wires will be). You may have to gently bend the wires to get them all on the same side.