--- /dev/null
+Reprap Wilson Assembly Guide
+Written by Martin Rice <mrice411@gmail.com>
+
+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
+
+* 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.
+
+5.3
+
+* 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. Mount X and Y motors
+
+7.1 In addition to the frame from the previous step, you will need:
+
+ a. Two NEMA17 stepper motors
+ b. Two belt pulleys
+ c. The two idler bearings and mounts
+ d. Three M3 x 10mm screws
+ e. Three M3 x 14mm screws
+ f. Two screws with lock nuts for mounting the belt idlers (probably M3 x 25mm)
+
+* Mount the motors, the pulleys, the idlers.
+* Mount the print bed you prepared earlier to the Y axis bearing holders
+ using Eight M3 x 14mm screws and an equal number of M3 nuts and washers.
+ 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.
+
+7.2 Attach the X carriage.
+
+You will need:
+
+ a. The printed X carriage
+ b. Eight miniature zip ties
+
+
+
HCoop / clinton / wilson.git / blobdiff