Ender 5 Plus SKR Conversion Kit

thingiverse

Summary ======= This is an electronics conversion kit for the Ender 5 Plus that will allow you to convert the electronics over to a SKR 1.3/1.4/Turbo, along with a Raspberry Pi 4b in a compact side-mounted electronics box. The electronics box is mounted on the inside of the back-right vertical 2040 extrusion, the Meanwell PSU is mounted on the inside of the back-left vertical 2040 extrusion, and the power socket and switch gets mounted on the bottom 2020 extrusion in the rear. Electronics Enclosure ================= The electronics enclosure is designed to fit: * 1 x SKR 1.3/1.4/Turbo board. * 1 x Raspberry Pi 4b * 2 x LM2596 DC-DC stepdown converters, for your 24v to 12v/5v needs. * 1 x Creality Bed Heater MOSFET Board (old design) * 1 x TH3D Mosfet Board (new design) https://www.th3dstudio.com/product/high-amp-12v-24v-mosfet-heated-bed-or-hotend/ * 1 x RossPeter.org Raspberry Pi to SKR Adapter Board https://www.tindie.com/products/pcr/reprapfirmare-raspberry-pi-to-skr-1x-adapter/ * 2 x 4010 Axial Fans for the SKR and the Pi * 1 x 5015 Blower Fan for the Stepper Driver cooling, along with an air duct built in to the lid. Meanwell PSU =========== The Meanwell PSU can be re-used from the stock configuration, and an adapter plate is included to mount the PSU against the inside of the back-left 2040 extrusion, with the fan facing up and the wiring terminals facing down. The stock power socket and power switch can also be re-used, and an enclosure box is included for both of those. A Snap-On terminal cover is also included, with access holes for the terminals and the screws. I suggest snapping the terminal cover on before inserting the wires. Hardware ======== I highly recommend Albany County Fasteners for all your metric screw needs, they're very high quality and are cheap in packs of 25/50/100. https://www.albanycountyfasteners.com/metric-socket-cap-screws/693.htm You will need an assortment of M2.5, M3, M4, and M5 screws and nuts. * 4 x M3 - 10mm screws and M3 nuts for the SKR. * 4 x M2.5 - 10mm screws and M2.5 nuts for the Raspberry Pi * 4 x M3 - 10mm screws and M3 nuts for the LM2596 boards. (2x each) * 2 x M4 - 10mm screws and M4 nuts for the Creality Mosfet Board. (old design) * 4 x M3 - 10mm screws and M3 nuts for the TH3D Mosfet Board (new design) * 4 x M3 - 10mm screws for the 4010 Axial Fans (2x each) * 2 x PC Fan screws for the 5015 Blower Fan, like these: https://www.amazon.com/Computer-Cooling-Mount-Screws-Pack/dp/B01LLKY3GO * 2 x M3 - 15-20mm screws for the lid hinges. * 10 x M5 - 10mm screws and M5 T-Nuts for 2020/2040 profile, for mounting the boxes. I recommend the roll-in kind with the spring loaded ball on the back. Power Wiring ========== Rather than re-use the existing wires, I would recommend creating new wiring to length, using the appropriate connectors: * Female Insulated Fork Terminals for the Power Supply ends. * Female Insulated Spade Terminals for the power socket and power switch ends. * Insulated Ferrules for the 24V DC ends going to the SKR. Do not use wiring without terminals/ferrules, as stranded wire is not designed to be clamped and it's a fire hazard. Update 7/31/2020 ----------------------- The design of the case has been updated a few times, with new features: * The sharp corners on the case have had circles added for helping with bed adhesion. They can be cut with a knife and snapped off after printing. * The 2 x 40mm fan holes on the top have been changed to accept M3 screws, with the common 4010 fans attached on the outside of the case. Added a notch to pass the fan wires through. * The top has been hinged, with holes for M3 screws to act as hinges. 15-20mm M3 screws will do. * The case closure mechanism in the front has been replaced with a 5mm hole for a M5 screw to be inserted through the front of the bottom case, to thread into the tab in the top. * The back mounting panel thickness has been increased from 5mm to 7mm to support the hinges, I had them snap off previously. Update 8/9/2020 ---------------------- The original case bottom design has been renamed "Ender 5 Plus Case Bottom - Creality Mosfet", to indicate that it is the version for mounting a Creality Mosfet board. A new version of the case bottom and top have been created, designed around a TH3D Mosfet board: https://www.th3dstudio.com/product/high-amp-12v-24v-mosfet-heated-bed-or-hotend/ Files: Ender 5 Plus Case Top - TH3D Mosfet.stl Ender 5 Plus Case Bottom - TH3D Mosfet.stl New features: * 4010 Fan has been relocated from over the Pi to over the Mosfet. * Cooling holes have been added above the Pi's side ports. * Power Input slot near the SKR's 12/24v input has been widened/made taller. * A hole in the cover has been made to fit the RossPeter.org Pi to SKR Adapter board: https://www.tindie.com/products/pcr/reprapfirmare-raspberry-pi-to-skr-1x-adapter/ Update 8/23/2020 ------------------------ Added a version of the case bottom to fit a Raspberry Pi 3/3B+ instead of a Pi 4B.