---------------------------------------------
-How to Assemble the Reprap Wilson 3D printer
-Written by Martin Rice <mrice411@gmail.com>
---------------------------------------------
-
-1. Identify the components
-
-2. Assemble the Y axis (part 1)
-
- The following parts are used during this step:
-
- a. The two M10 threaded rods
- b. The Y axis smooth rods
- c. The plastic Y end pieces (2)
- d. The two plastic frame brace supports
- e. 12 M10 nuts and washers
- f. Four linear bearings (LM8UU)
-
-3. Assemble the Frame (part 1)
-
- The following parts are used during this step:
-
- a. The two side pieces of 2020 aluminum extrusion (the longer ones, generally)
- b. One of the two horizontal pieces of 2020 aluminum extrusion (the shorter ones, generally)
- c. 36 T-slot nuts
- d. 28 M5 x 8mm screws
- e. The plastic Z motor holders (2)
- f. The plastic rear frame brackets (2)
-
-4. Mount the Y axis to the frame
-
-5. Assemble the X axis (part 1)
-
-6. Mounting the X axis to the Z axis
-
-7. Assemble the Frame (part 2)
-
-
-
-
-
+Reprap Wilson Assembly Guide
+Written by Martin Rice <mrice411@gmail.com>
+
++ For the latest version of this document, check the "docs" folder at +
++ https://github.com/mjrice/wilson +
++ +
++ Please refer to the wilson-bom spreedsheet for a comprehensive list of +
++ parts needed before you begin. +
++ +
++ You will find photos of most of the steps below indexed by the step +
++ number, located in the images/ folder. +
+
+1. Assemble the Y axis (part 1)
+
+1.1 Gather the following parts
+
+ a. The two M10 threaded rods
+ b. The Y axis smooth rods
+ c. The plastic Y end pieces (2)
+ d. The two plastic frame brace supports
+ e. 12 M10 nuts and washers
+ f. Four linear bearings (LM8UU)
+
+1.2 Hardware Assembly
+
+* Slide a brace support onto each threaded rod. On each side of the
+ supports, put a washer, a nut, another nut and another washer (in
+ that order).
+* Next, slide two two Y end pieces over the ends of the threaded rods.
+ Place a washer then nut on each end.
+
+1.3 Tightening the Y axis
+
+* Start at one end (either Y motor or Y idler end) and tighten the two
+ nuts against the end so that the threaded rod is flush with the outside
+ of the nut. Tighten both sides of the first end while everything else
+ is loose along the threaded rods. Use two wrenches to tighten the nuts
+ against the end until snug (tight, but don't compress enough to deform
+ or break the plastic).
+* Place two linear bearings on each Y axis smooth rod.
+* Next, with the other Y end still loosely attached, place the two Y axis
+ smooth rods across the top and fit into the grooves along the top of
+ the ends.
+* Press down on the corners (not in the middle of the rods!) to seat the
+ rods into the Y ends.
+* Tighten one corner of the remaining end.
+* Now take a moment to measure with a ruler between the end posts of the
+ tightened side. (355mm for reference).
+* Flip the assembly around and repeat the measurement as you tighten the
+ remaining corner (tighten it just a little first, then measure. If the
+ distance is a little less than the first side, tighten the inner nut
+ outward toward the outer nut, if the distance is a little more than the
+ first side, then tighten the outer nut toward the inner one. Try to get
+ the two sides as close to the same distance as possible. This will help
+ ensure your y axis bearings don't experience any binding forces).
+* Repeat the measurement on the first side and check that all corners are
+ nice and snug. Take your time on this step, it may require a couple
+ iterations to get the axis square.
+
+1.4 Prep the Print Bed
+
+While the Y axis assembly is free, it is a good time to prepare the print
+bed which you will attach later.
+
+Gather the following materials
+
+ a. The Y axis assembly you just completed
+ b. The wood print bed support
+ c. The heat bed
+ d. The four linear bearing holders
+ e. Eight miniature zip ties
+
+* Place the heat bed circuitboard over the wood bed and mark the four
+ corner locations with a pencil.
+* Put the heat bed circuitboard aside and place the four linear bearing
+ holders over the linear bearings along the Y axis rods.
+* Turn the Y axis assembly over so that the smooth rods (and bearing
+ holders) are against the wood print bed surface.
+* Align the front edge of the two bearing holders nearest the Y end idler
+ with a line that is 80mm from the front edge of the bed.
+* Align the back edge of the two bearing holders nearest the Y end motor
+ mount with a line that is approx 10mm from the back edge of the bed.
+* Mark all the holes for the bearing holders with a pencil.
+* Remove the wood print bed and drill all the holes you marked with a 5mm
+ drill bit. (You want the holes a little over-sized so that there is
+ some room for the screws to "float" when you attach the bed).
+* Attach the linear bearing holders to the Y axis linear bearings with
+ zip ties.
+
+Set the prepared wood print bed aside.
+
+2. Assemble the Frame (part 1)
+
+2.1 Gather the following parts
+
+ a. The two side pieces of 2020 aluminum extrusion (the longer ones,
+ generally)
+ b. One of the two horizontal pieces of 2020 aluminum extrusion (the
+ shorter ones, generally)
+ c. 22 T-slot nuts
+ d. 14 M5 x 8mm screws
+ e. The plastic Z motor holders (2)
+ f. The plastic rear frame brackets (2)
+
+2.2 Hardware Assembly
+
+* Slide 6 T-nuts into one side of the shorter extrusion (this wlll be the
+ bottom piece of the frame).
+* Turn the extrusion over (being careful not to let the nuts slide out
+ that you just put in) and slide 8 more nuts into the opposite side that
+ you begain with.
+* Place the two remaining extrusions to the sides of the first, and slide
+ two T nuts into each on the side facing up.
+* Get the two corner braces and place one over each corner. Line up the
+ two nuts on each extrusion and attach the braces with a total of 8 M5
+ screws. Note that the longer extrusions (the "sides" of the frame)
+ should cover the ends of the bottom extrusion piece. Leave the screws
+ loose until all 8 are started.
+* Stand the frame "upright" to ensure the sides are slid down flush with
+ the bottom and alternately tighten until all the screws are tight.
+* Rotate the frame so the other side is facing you and put it back flat
+ on your work surface.
+* Slide two more T nuts into each side piece and attach the motor mounts
+ the same way you did the rear brackets, using 6 more M5 screws.
+* You should have four T nuts sliding around between the lower corners,
+ which will be used to attach the Y axis to the frame in the next step.
+
+
+3. Mount the Y axis to the frame
+
+3.1 The following parts are used during this step:
+
+ a. The partially-assembled Y axis from step 1.
+ b. The partially assembled frame from step 2.
+ c. Eight M5 x 8mm screws
+
+3.2 Mounting the Y axis
+
+* Place the Y axis over the frame so that the Y motor end is toward the
+ rear, and the Z motor brackets are toward the front.
+* Slide the Y axis along the threaded rods so that there is ** 135mm **
+ from the Y motor end and the frame braces
+* Tighten the nuts on the first side finger-tight against the frame brace
+ then turn the assembly around and repeat on the other side. Measure a
+ couple times to make sure the distance from the y motor end to the frame
+ braces is the same on each corner. Next slide the Y axis assembly left
+ or right along the lower frame extrusion so that there is ** 50mm **
+ from the upright extrusion to the inner edge of the frame brace on the
+ "left" side of the printer (as viewed with the Y axis idler toward you).
+* Tighten the frame braces using 8 M5 screws into the T slot nuts that
+ are alread in the lower frame extrusion. Finish tightening the nuts of
+ the threaded rod against the braces, double-checking that the distance
+ from the Y end to the braces is the same on each side. A convenient
+ place to measure this after the nuts are snug is from the inside of the
+ nuts (approx 116mm).
+
+4. Assemble the X axis (part 1)
+
+4.1 Gather the following parts:
+
+ a. The two plastic X end pieces ("motor" and "idler")
+ b. Eight linear bearings (LM8UU)
+ c. The two X axis smooth rods
+ d. Two M5 nuts
+ e. X endstop limit switch
+ f. One M3 x 30mm screw and nut
+ g. One spring
+
+4.2 Hardware Assembly
+
+* Press two linear bearings into each X end.
+* Using pliers, gently press an M5 nut into the provided insert in each
+ end.
+* Place two linear bearings on each of the smooth rods.
+* Insert the X endstop switch (previously wired) into the slot provided
+ on the X motor end. Route the wires down and through the guide on
+ the bottom side of the end. Secure with a zip tie.
+* Press an M3 nut into the bottom of the Z axis adjuster, then thread
+ an M3 x 30mm screw through a spring and into the nut from the top side.
+* Press each X end onto the pair of smooth rods, being sure to orient
+ them so that the M5 nuts are on the same side of the rods.
+
+5. Assembling the frame (part 2)
+
+5.1 Gather the following:
+
+ a. The two upper Z axis mounts.
+ b. The remaining piece of aluminum extrusion (the top bar)
+ c. Four t-slot nuts
+ d. Five more t-slot nuts if you are going to use the filament holder
+ and SMART electronics mount.
+ e. Four M5 x 8mm screws
+
+5.2 Assembly
+
+* Insert two t-slot nuts into the top side of the aluminum extrusion.
+* If you will be using the filament holder, rotate the extrusion 90
+ degrees and insert two more t-slot nuts into the top side.
+* Insert the remaining t-slot nuts into the side opposite from the one
+ you started with.
+* Attach the upper Z axis mounts to the ends of the extrusion, tightening
+ the M5 nuts just until snug. Be sure to keep the two t slot nuts for
+ the filament holder on the "top" and the t slot nuts for the SMART
+ electronics mount and filament holder to the back (side away from the
+ rod holders).
+
+6. Mounting the X axis to the Z axis
+
+6.1 Gather the following
+
+ a. The partialy assembled frame from step 3.
+ b. The X axis assembly from step 4.
+ c. The upper frame assembly from step 5.
+ d. The remaining two smooth rods
+ e. The Z axis threaded rods (M5)
+ f. Two NEMA17 stepper motors
+ g. Eight M3 x 10mm screws (washers recommended)
+ h. Two Z axis couplers (either 5mm x 5mm couplers or 3/16" vinyl tubing)
+ i. Eight t-slot nuts
+ j. Eight M5 x 8mm screws
+
+6.2 Mounting the X axis onto the frame.
+
+* Attach the two Z axis motors to the motor mounts using four M3 x 10mm
+ screws each. Place the z axis couplers on each motor shaft.
+* Press each Z axis smooth rod firmly down into the rod holder of each motor
+ mount, being careful to keep the rods straight up and down to avoid
+ breaking the mounts.
+* Gently slide the X axis assembly down over the Z axis rods. If the linear
+ bearings in each X end do not align with the Z axis rods, remove the X
+ axis assembly and gently push/pull the two ends to get the distance right.
+ The motor end of the X axis assembly should be on your left (with the Y
+ idler end toward you).
+* Insert two t-slot nuts into both the front and back sides of each end (8
+ total). You may want to hold the frame assembly on your lap with the
+ upright extensions horizontally at the point, so that the t slot nuts
+ don't slide down to the botttom of the frame. If they do, simply place
+ your hands over the tops of the extrusions, keeping the z axis smooth
+ rods supported, and tip the assembly over to slide the nuts back toward
+ the top.
+* Place the upper frame assembly on the frame. Fit the tops of the z axis
+ smooth rods into the rod holders.
+* Secure the top of the frame using 8 M5 x 8mm screws. Be sure to press
+ the top of the frame down securely onto the vertical extrusions, and
+ then press inward on each top corner to seat the upper extrusion against
+ the sides.
+* With the X axis assembly resting at the bottom of the Z axis smooth
+ rods, thread the z axis threaded rods down through the nut in each X
+ end until the threaded rods rest against the Z axis motor shafts.
+* Tighten the z axis couplers.
+
+7. Completing the Frame Assembly
+
+7.1 Mount X and Y motors
+
+* In addition to the frame from the previous step, gather the following:
+
+ a. Two NEMA17 stepper motors
+ b. Two belt pulleys
+ c. The two idler bearings and plastic bearing guides
+ d. Three M3 x 10mm screws
+ e. Three M3 x 14mm screws
+ f. Two M4 x 20mm screws and nuts
+
+* Mount the motors to the X and Y axis motor mounts using three screws
+ each.
+* Fit a pulley on each motor shaft and tighten the grub screws to keep
+ them secure.
+* Snap an idler bearing into each pair of plastic bearing guides, then
+ attach the idlers to the opposite ends of the X and Y axis from where
+ you attached the motors. Don't overtighten the screws that hold on
+ the idlers.
+
+7.2 Attach print bed
+
+* You will need:
+
+ a. The print bed you prepared earlier.
+ b. Eight M3 x 14mm screws and an equal number of M3 nuts and washers.
+
+* Mount the print bed to the Y axis bearing holders. The washer should
+ go on the screw first, which should go downward through the wood print
+ bed and bearing holder, and secured with a nut. Attach each screw only
+ loosely first, then check that the bed slides smoothly back and forth
+ along the Y axis. Tighten the nuts a little at a time until secure.
+
+7.3 Attach the X carriage.
+
+* You will need:
+
+ a. The printed X carriage
+ b. Eight miniature zip ties
+
+* Attach the X carriage with the belt guide "up" and with the flat
+ surface (where you will attach the extruder) toward the front of the
+ printer (the Y idler end).
+
+7.4 Attach Belts
+
+* You will need:
+
+ a. The X axis drive belt
+ b. The Y axis drive belt
+ c. The Y belt holder
+ d. 8 Miniature zip ties
+
+* Thread the X axis belt into place and secure with four zip ties (two
+ on each side of the extruder, trimmed short after tight).
+* Turn the printer over or have a friend hold it upside down, being
+ careful not to lift by or put pressure on the X axis rods.
+* Thread the Y axis belt into place. Hold the belt tight and use as a
+ guide for placing the Y belt holder. The leading edge of the belt
+ holder should be approximately in the middle of the wood print bed.
+* Mark the holes for the Y belt holder, then set the holder and belt
+ aside and drill the two holes with a 4-5mm hand drill.
+* Attach the Y belt holder with the head of the screws to the bottom,
+ with a washer and nut on the wood side.
+
+7.5 Attach accessory mounts
+
+* You will need:
+ a. Filament holder mounts
+ b. SMART display mounts
+ c. RAMPS electronics frame mount
+ c. Eight M5 x 8mm screws
+
+7.6 Attach heat bed
+
+* You will need:
+
+ a. The heat bed circuitboard
+ b. Four M3 x 30mm screws and locknuts
+ c. Four springs (approx 1" long uncompressed)
+
+* This is a good time to attach the heat bed thermistor if you have not
+ already done so. Depending on your heat bed and thermistor, the most
+ likely procedure here is to secure the thermistor to the middle of the
+ bottom-side of the heat bed with a strip of Kapton tape.
+* Attach the heat bed with a screw through each corner, with the head of
+ the screw up, down through the heat bed, through a spring, then through
+ the wood print bed, and into a lock nut. Compress the springs about
+ halfway (you will adjust each corner later to level the bed more
+ precisely).
+
+7.7 Attach Limit Switches
+
+* You will need:
+
+ a. Three micro limit switches
+ b. The Z axis limit switch mount
+ c. One T-slot nut and M5 x 8mm screw
+ c. M2 x 16mm screws and nuts as needed (up to 6 each)
+
+* If your limit switches do not already have wires attached, do that
+ now. You will need approximately 45cm (18") of wire on each switch
+ (depending on where you locate the electronics).
+
+* Slide a T nut into the outer side of the left upright piece from
+ the bottom. Attach the Z endstop holder with a M5 x 8 screw.
+
+8. Extruder Assembly and Mounting
+
+8.1 Assemble the Extruder
+
+* You will need:
+
+ a. The extruder body and idler.
+ b. The hot end.
+ c. The M8 Hobbed bolt
+ d. Two M8 nuts (or one M8 locknut), and washers (probably 4).
+ e. Two springs (approx 1" long uncompressed)
+ f. The M8 x 20mm smooth rod (or M8 x 20mm grub screw)
+ g. Three 608 bearings
+ h. Two M3 x 60mm screws
+ i. The larger extruder gear.
+ j. Three M3 x 30mm screws
+ k. Five M3 nuts
+
+* If your hot end was not previously assembled (heater resistor and
+ thermistor), do that now. Follow the instructions for your particular
+ hot end.
+* Slide the M8 x 20mm shaft through a 608 ball bearing then push this
+ assembly inside the extruder idler. You may have to use pliers to snap
+ the shaft into place. Apply even pressure on top of the shaft/bearing
+ to avoid cracking the plastic idler.
+* Insert an M3 nut into the inner recess provided on the idler. Use
+ pliers or a hot iron to fix the nut into place (be careful not to break
+ the idler in the process).
+* Thread an M3 x 30mm screw through the outer side of the idler on the
+ side you just inserted the nut, just until the screw starts into the
+ nut.
+* Fix the idler assembly to the Wade Body Extruder and then finish
+ screwing the M3 x 30 bolt all the way through the fulcrum support.
+
+* Slide the Wade Big Gear through the hobbed bolt so that the hex head of
+ the bolt is secured in the recess of the big gear. Slide 3-5 M8 washers
+ onto the bolt (they go between the gear and the body of the extruder to
+ provide spacing) followed by one 608 bearing. Insert the bolt into the
+ extruder body, securing the bearing in the hole provided. Add another
+ 608 bearing on the loose end of the bolt, followed by another M8 washer
+ and locknut. Tighten the lock nut just enough to keep the hobbed bolt
+ in place; it should spin freely.
+
+* Insert two M3 nuts in their slots on the top of the extruder body.
+ Place an washer, then spring, then another washer on each M3 x 60mm
+ screw, then thread the screws through the slots of the idler and into
+ the nuts you inserted in the extruder body. Tighten the screws until
+ the springs are well compressed (this keeps tension on the printer
+ filament). If either spring is too short (or the bolts are too long)
+ to compress properly, remove the bolt and place an M3 nut on first
+ (before the washer/springs).
+
+* Insert the hot end into the 16mm hold on the bottom of the extruder.
+
+* Secure the hot end to the extruder body by threading in two M3 x 30mm
+ screws through the front of the extruder (they will pinch the sides of
+ the hot end on their way through the plastic body). Secure with M3
+ nuts and tighten well (it is critical that the hot end be rigid and
+ not wobbly).
+
+8.2 Connecting extruder to X-axis
+
+* You will need:
+
+ a. Extruder assembly
+ b. Wade Small Gear
+ c. One NEMA 17 motor
+ d. The plastic fan duct.
+ e. One 40mm x 40mm x 10mm fan.
+ f. Four M4 x 25 mm screws
+ g. Four M4 nuts
+ h. One M3 x 30mm screw
+ i. Seven M3 x 14mm screws
+ j. Three M3 washers
+ k. One M3 x 8mm screw
+ l. Five M3 nuts
+ m. One M3 locknut
+
+* Insert two M4 nuts in the bottom of the extruder body in the slots
+ provided. Use pliers to gently press the nuts into the plastic, or
+ press them in with the tip of a hot soldering iron if the holes are
+ too tight.
+* Insert two M4 nuts into the slots on the sides of the extruder body.
+* The extruder is held to the X carriage by the four M4 x 25mm screws.
+ Insert the four screws through the back of the X carriage and then
+ slide on the extruder assembly (thread the top two screws into the
+ nuts you just inserted). Then screw the two lower M4 nuts into
+ place and tighten all four screws.
+* Insert an M3 nut into the slot on the small gear. Use pliers or a hot
+ iron to press into place if necessary.
+* Slide the small gear onto the shaft of the NEMA 17 motor. If
+ necessary, drill out the shaft hole on the small gear with a 5mm drill
+ bit.
+* Insert the M3 x 8mm screw and tighten against the shaft of the motor.
+* Place the motor assembly against the Wade Extruder Body (supply wires
+ upwards). Insert three M3x14 mm screws and three Ø3 mm washers without
+ tightening. Slide the motor assembly against the Wade Big Gear and
+ tighten the screws to hold the motor secure.
+* Attach the 40mm fan to the fan duct using four M3 x 14mm screws and
+ M3 nuts. Make sure the fan is oriented so that airflow is going toward
+ the duct (usually this means the side of the fan with a label on it
+ will be against the fan duct).
+* Fix the Fan Duct assembly on the Wade Extruder Body with an M3 30mm
+ screw and an M3 lock nut. Do not overtighten.
+
+8.3 Install glass bed
+
+* Now is a good time to install the glass bed. Place the glass on top
+ of the heat bed and secure with four paper-binder clips. If the X axis
+ is too low, you may have to manually turn the two Z axis rods to lift
+ it high enough so that the glass will fit underneat the hot end nozzle.
+
+9. Connect the Electronics
+
+* You will need:
+
+ a. The electronics controller of your choice (e.g. RAMPS)
+ b. The power supply
+ c. SMART display (optional)
+
+* Use the checklist below as you connect the electronics. If your
+ electronics board has multiple options for connecting devices, make a
+ note of which connection you use so that you can input the settings
+ to your firmware.
+
+ [ ] X axis stepper motor
+ [ ] Y axis stepper motor
+ [ ] Z axis stepper motors (2)
+ [ ] Extruder stepper motor
+ [ ] X axis limit switch
+ [ ] Y axis limit switch
+ [ ] Z axis limit switch
+ [ ] Heat bed power
+ [ ] Extruder heater power
+ [ ] Extruder fan power
+
+
+
+
+
+
+
+
+
+
+
HCoop / clinton / wilson.git / blobdiff