[clinton/wilson.git] / doc / how-to-build.txt

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     

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. 
*       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