3FPD-Replicator 2X - Extruder Upgrade

thingiverse

This is an extruder upgrade designed specifically for the Replicator 2X similar to whpthomas, and others, but with improvements. update Rev 3 http://www.thingiverse.com/thing:111711 -base is fully printable without supports -arm is printable with only external supports (bearing slot) -arm integrates feed tube mount as well -tension spring geometry improved -use 5/32" and 1/4" bits for tight clearance bearing/arm pivot holes -uses Makerbot hardware kit for Rep2 + 1 extruder screw ($8 ea from Makerbot.com) -can be pre-assembled for quick swap (under 2 minutes each) -L and R extruder parts included, and labelled (common pin) Instructions -Acquire the Rep2 extruder upgrade kit hardware only. ($8 ea shoudler bolt, small FH screw, bearing, spring) from Makerbot -I printed it at 0.27mm layer with no support on base, and external supports for the arm just because of the bearing channel. -you will need to chase the bore for the bearing shoulder bolt with a 5/32" drill bit just to make sure it is a tight fit. -you may need to chase the 1/4" pivot hole in the arm to make sure it is a tight fit as well. -you will need to lightly file the pin flats, and round edges to make it fit tight into the base key slot -the base key slot has a relief at the bottom to make sure the pin seats flush and square with no radius in the corners Pre-Assembly: -included parts are LH-Arm, LH-Base, RH-Arm, RH-Base, and a common pin (print 2 of them, and one each of the others) -put the small flathead screw into the deep corner countersunk hole in the base part. -put the pin into the arm part so it is flush on the outside face -put the bearing into the arm slot and secure with the shoulder bolt -shoulder bolt head should be flush to the outside face, and the threads should stick out the back -bearing should spin freely -put arm onto base rotating the pin so the shoulder bolt threaded end rests in the curved slot in the base face. now that the movement is limited in the arm via the threaded end in the slot you can add the spring -place the spring on the bottom perch and compress it into the arm perch. pre-assembly complete. -follow makerbot instructions on how to remove the existing extruder. -place the newly pre-assembled extruder upgrade onto the stepper. You may have to compress the arm slightly to move the bearing out of the way of the drive gear. -new extruder should seat flush to the stepper face. -use one of the long flathead screws from the removed Makerbot extruder through the corner pin to secure the new 2X extruder upgrade to the stepper. -tighten until snug, but arm moves freely with very slight resistance. -press the arm down until you can insert the hex-key though the arm hole to tighten the small flathead screw in the other corner. -repeat entire procedure for the extruder upgrade for the other side. Please let know if you have any suggestions on improvements.