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My Replikeo Prusa i3 Rework Build

Posted by Trike 
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 01:00AM
Quote
gadget_greg
The excess is not a problem, the whole idea is that the smooth rods are parallel, at the same width on both ends, and the same width as the linear bearings attached to the heated bed mount. You can keep them slightly loose until you get the bed moving smoothly then tighten them up.

I ended up replacing my upper threaded rod on the back end with a 5/16" (or was it 3/8"?) rod that was a couple inches longer so I could install the z-stabilizer that Tech2C posted earlier in this thread. It works great! [forums.reprap.org]

Oh cool. I didn't *think* it was a problem, but wanted to ask to be sure. I also realized I said 186mm, but that figure is wrong. 186mm is the width between legs on the short side (which mine is). The length is more like 320mm or something. In either case, I lined up everything parallel, shortened the length so that the smooth rods are nice and snug in the legs, and I'm just going to ignore the extra length on the threaded rods. As long as all my widths are the same, I should be fine, like you said tongue sticking out smiley Thanks!

Also, wow! That looks like a great idea with those z-stabilizer rods. I may wind up adding those at some point to mine.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 01:07AM
They definitely stiffen the whole thing up a lot!
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 01:39AM
Quote
gadget_greg
They definitely stiffen the whole thing up a lot!

Cool! I will definitely look into it. First I have to figure out why one of the y-corner legs is not sitting flush with the table while the other 3 are tongue sticking out smiley
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 04:11AM
Looks like I've run into a roadblock. Apparently Replikeo decided to send me only 1 m3x8 grub screw. At least I think that's all they sent me. There are a total of 2 headless screws in the plastic baggies (that's them, right? Also called 'set screws?') One is tiny and dark and the other is much fatter and about 4x the length of the small one. I'm guessing one is the m3 and the other is the m8, but only one m3 instead of the 5 the BOM lists. How am I supposed to secure the couplers without them? Just for giggles, I did try and fit the tiny one into one of the holes on one of the couplers and it didn't even fit. I know that the local Home Depot sells set screws, so maybe I can try over there. The build instructions have zero pictures for that section and don't even list the grub screw's size. *sigh* I am halfway there. So close! *shakes fist*
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 04:13AM
Quote
LittleMike
Looks like I've run into a roadblock. Apparently Replikeo decided to send me only 1 m3x8 grub screw. At least I think that's all they sent me. There are a total of 2 headless screws in the plastic baggies (that's them, right? Also called 'set screws?') One is tiny and dark and the other is much fatter and about 4x the length of the small one. I'm guessing one is the m3 and the other is the m8, but only one m3 instead of the 5 the BOM lists. How am I supposed to secure the couplers without them? Just for giggles, I did try and fit the tiny one into one of the holes on one of the couplers and it didn't even fit. I know that the local Home Depot sells set screws, so maybe I can try over there. The build instructions have zero pictures for that section and don't even list the grub screw's size. *sigh* I am halfway there. So close! *shakes fist*

For me, the couplers already have grub screws in them. I only need one m3x8 grub screw for the extruder small gear.

There are also 4 much smaller grub screws in the bag with the belts, used to secure the pulleys.

Edit: Also have the M8 one used to support one of the extruder bearings.

Edited 1 time(s). Last edit at 08/21/2014 04:21AM by alvinhochun.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 04:20AM
Quote
alvinhochun
Quote
LittleMike
Looks like I've run into a roadblock. Apparently Replikeo decided to send me only 1 m3x8 grub screw. At least I think that's all they sent me. There are a total of 2 headless screws in the plastic baggies (that's them, right? Also called 'set screws?') One is tiny and dark and the other is much fatter and about 4x the length of the small one. I'm guessing one is the m3 and the other is the m8, but only one m3 instead of the 5 the BOM lists. How am I supposed to secure the couplers without them? Just for giggles, I did try and fit the tiny one into one of the holes on one of the couplers and it didn't even fit. I know that the local Home Depot sells set screws, so maybe I can try over there. The build instructions have zero pictures for that section and don't even list the grub screw's size. *sigh* I am halfway there. So close! *shakes fist*

For me, the couplers already have grub screws in them. I only need one m3x8 grub screw for the extruder small gear.

There are also 4 much smaller grub screws in the bag with the belts, used to secure the pulleys.

Genius! I didn't even think of that. I thought I had to screw them in. I just stuck my allen wrench in one of the holes and turned, and sure enough, the threaded rod stopped on the coupler! Thank you so much!

I will have to look again for the other grub screws for when I get to the belts. So far I've done X-axis assembly, Y-axis, join X and Z, and now I'm doing the motor assembly, but I might just call it a night. It's past 4am over here. Haha
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 05:23AM
Okay, so I didn't go to bed tongue sticking out smiley I am now, though, as I give up for one night. These sainsmart endstops are the worst. I can't figure out how to mount the z endstop holder and endstop. Any ideas?
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:36AM
Help!
Something just burned out on my RAMPS board (I think). I was calibrating bed, when fan went silent and PSU light went off. I thought PSU burned out, but when I disconnected it from RAMPS it was working and I'm getting 12V on all outputs.
As soon as I plug it in, power LED goes out.
I took everything apart, and tried plugging just RAMPS board into PSU (Arduino is physically disconnected from RAMPs). This time PSU didn't die, but LED4 on RAMPS is lit up. I traced LED4 to D10 (extruder), and I can see 12V on it. Does it mean MOSFET powering D10 is dead? As far as I'm aware that LED4 should not be lit when Arduino is not plugged into this shield...

Update: Yeah it looks like MOSFET is fried, I'm getting short circuit between all 3pins on it...
I happen to have STP16NF06 on hand, (which not as powerful as STP55NF06L). It's only rated for 16A and power dissipation 45W, is it safe to use for HotEnd?

Edited 2 time(s). Last edit at 08/21/2014 12:15PM by Bratan.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 12:23PM
Hey Bratan, sorry to hear that, that sucks. I wish I could help. I've replaced my Mega/RAMPS once already myself.

Mike, that z-endstop holder is a really poor design, which is only compounded by the poor design of the endstop itself. The only suggestion I have is to figure out a way to rig it up to work for a while (like I did) then as soon as you can print yourself one of these... [www.thingiverse.com]

Greg
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 01:12PM
Quote
gadget_greg
Hey Bratan, sorry to hear that, that sucks. I wish I could help. I've replaced my Mega/RAMPS once already myself.

Mike, that z-endstop holder is a really poor design, which is only compounded by the poor design of the endstop itself. The only suggestion I have is to figure out a way to rig it up to work for a while (like I did) then as soon as you can print yourself one of these... [www.thingiverse.com]

Greg

Thanks for the link. That looks like a much better design. I'll try zipties or something just to get it to sit for now and continue on. Gotta keep building! Haha
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 10:47PM
My z end stop fit perfectly on the stepper motor mount. Y axis never was correct. Would be nice if it was easier to adjust though.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:06PM
Quote
underthetire
My z end stop fit perfectly on the stepper motor mount. Y axis never was correct. Would be nice if it was easier to adjust though.

How did you attach yours? Didn't your kit come with the same Sainsmart endstops? You can't screw them in to the holder because of the stupid connector. I ziptied mine for now. It's not a great solution, but until I can print out a different z endstop holder, it'll have to do tongue sticking out smiley
Attachments:
open | download - z end stop-1.jpg (428.3 KB)
open | download - z end stop-2.jpg (455.8 KB)
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:12PM
Easy, plug in the cable and bend the connector pins. Now you can screw the screws.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:16PM
Quote
alvinhochun
Easy, plug in the cable and bend the connector pins. Now you can screw the screws.

Yea, but you have to have the nuts on that side, not the head of the screw. The nut alone is too wide and the screws are too long. How did you get around that? I was able to do that for the X-axis, but not the Z
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:17PM
Quote
LittleMike
Quote
alvinhochun
Easy, plug in the cable and bend the connector pins. Now you can screw the screws.

Yea, but you have to have the nuts on that side, not the head of the screw. The nut alone is too wide and the screws are too long. How did you get around that? I was able to do that for the X-axis, but not the Z
Bend more. Try harder.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:21PM
Quote
alvinhochun
Quote
LittleMike
Quote
alvinhochun
Easy, plug in the cable and bend the connector pins. Now you can screw the screws.

Yea, but you have to have the nuts on that side, not the head of the screw. The nut alone is too wide and the screws are too long. How did you get around that? I was able to do that for the X-axis, but not the Z
Bend more. Try harder.

The endstops are cheap. I didn't want to risk snapping the connector off.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:23PM
Quote
LittleMike
Quote
alvinhochun
Quote
LittleMike
Quote
alvinhochun
Easy, plug in the cable and bend the connector pins. Now you can screw the screws.

Yea, but you have to have the nuts on that side, not the head of the screw. The nut alone is too wide and the screws are too long. How did you get around that? I was able to do that for the X-axis, but not the Z
Bend more. Try harder.

The endstops are cheap. I didn't want to risk snapping the connector off.

Well if you really snap the connector off, then solder a straight connector which makes your life much easier. Or you can just keep using the zipties before you print another z endstop holder.
Re: My Replikeo Prusa i3 Rework Build
August 21, 2014 11:29PM
Quote
alvinhochun
Quote
LittleMike
Quote
alvinhochun
Quote
LittleMike
Quote
alvinhochun
Easy, plug in the cable and bend the connector pins. Now you can screw the screws.

Yea, but you have to have the nuts on that side, not the head of the screw. The nut alone is too wide and the screws are too long. How did you get around that? I was able to do that for the X-axis, but not the Z
Bend more. Try harder.

The endstops are cheap. I didn't want to risk snapping the connector off.

Well if you really snap the connector off, then solder a straight connector which makes your life much easier. Or you can just keep using the zipties before you print another z endstop holder.

That's true. Realistically, they should have straight header pins, not that angled connector, but well, flawed design. Especially given that the mount holes are covered by the connector tongue sticking out smiley With the holder that Greg linked earlier, it solves that problem, though. So I'll probably just stick with the zip ties for now and just replace the holder with a better designed one.
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 12:22AM
Ya, a butter knife under it, they bend pretty well.
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 01:11AM
I just built this for the y-axis. Looks pretty slick. [www.thingiverse.com]
I'll install it in a few days when I roll out several other new upgrades. winking smiley
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 02:10AM
Quote
underthetire
Ya, a butter knife under it, they bend pretty well.

I may do that later. I'm too excited to get it up and running first. I can tweak after tongue sticking out smiley

That's a sweet looking tensioner.
*EDIT* - That tensioner is for the T2.5 belt, not GT2
**************

I'm debating on starting on the belts or hit the rack. This thing has been beating me up. I had to run to Home Depot to get a 1.5mm allen key for the pulley grub screws. Currently staring at this:

Edited 1 time(s). Last edit at 08/22/2014 02:13AM by LittleMike.
Attachments:
open | download - Prusa i3 Rework - body.jpg (95.7 KB)
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 09:46AM
I see your z-axis smooth rods are too long as are your y-axis threaded rods. Perhaps your smooth rods should be switched? I probably wouldn't do it now, but sometime in the future you'll likely do a rebuild (I'm about to) and you might want to switch them around. Until then your y-axis will be a little smaller (not really a big deal unless you plan some big prints right out of the gate).
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 09:49AM
I didn't see your comment about the tensioner. Shit. Well, I'm not sure it'll matter that much really, I can probably make it work. winking smiley
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 11:34AM
LittleMike you probably used Y smooth rods as Z rods and vice versa
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 11:59AM
Oh shoot, are they? How can you tell? That must have been my problem when I posted about having an extra inch or so after the outside nuts. Dangit!
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 01:04PM
I've almost done the physical construction and electrical connections, though there are two things I must say:

1. The default MOSFET for the heated bed on the RAMPS is not suitable since it gets really hot, mine gets to 180°C and above (the rated operating temperature is only 175°C). You should either get a better MOSFET or use a relay or ssr rated at at least 15A.

2. The wires that is pre-soldered on the PCB heated bed (at least for mine) is probably too thin and will get hot with the high current. You should get thicker wires (should be mentioned somewhere on the forum or wiki but I think at least AWG16 is safer.)
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 01:34PM
Quote
gadget_greg
I see your z-axis smooth rods are too long as are your y-axis threaded rods. Perhaps your smooth rods should be switched? I probably wouldn't do it now, but sometime in the future you'll likely do a rebuild (I'm about to) and you might want to switch them around. Until then your y-axis will be a little smaller (not really a big deal unless you plan some big prints right out of the gate).

Okay, so that was easy enough to switch out because the smooth rods are basically "pressure fit" so to speak anyway. I undid the nuts on the threaded rods on all 4 corners and slid the assemblies out to free those smooth rods, and for the Z axis, I just gently worked them out of the corner and pulled them out. Swap, tighten, fixed grinning smiley

So my Z axis ones are basically flush with the frame holders. Is that correct? They are the 320's (the smaller of the two pair).
Re: My Replikeo Prusa i3 Rework Build
August 22, 2014 02:16PM
Quote
gadget_greg
Hey Bratan, sorry to hear that, that sucks. I wish I could help. I've replaced my Mega/RAMPS once already myself.

Mike, that z-endstop holder is a really poor design, which is only compounded by the poor design of the endstop itself. The only suggestion I have is to figure out a way to rig it up to work for a while (like I did) then as soon as you can print yourself one of these... [www.thingiverse.com]

Greg

No worries, I ordered few from Mouser, should be here tomorrow (I hope). I gotta print me that endstop, gonna be first thing I do after I resurrect my printer smiling smiley

Question to all know might know. Is it bad to short MOSFET's heatsinks between each one? I thought they just connected to the ground. I'm asking because my MOSFET burned out not when I was using hotend, but right after I added alum. heatsink to it. I bent transistor slightly, so I can attach heatsink to it, but it was touching other MOSFET's built in HS.

Quote
gadget_greg
I ended up replacing my upper threaded rod on the back end with a 5/16" (or was it 3/8"?) rod that was a couple inches longer so I could install the z-stabilizer that Tech2C posted earlier in this thread. It works great! [forums.reprap.org]
M8= 5/16", M10=3/8". Here's useful conversion chart. Made me realize that I can probably build whole thing with imperial rods smiling smiley I also plan to build Z-stabilizer, it could be what's causing my bad print shifts... Is Tech2C's stabilizer same as this one?

Edited 2 time(s). Last edit at 08/22/2014 02:58PM by Bratan.
Re: My Replikeo Prusa i3 Rework Build
August 23, 2014 12:23AM
So the build is on hold temporarily until I can get some better zip ties. I redid my smooth rods, that was easy enough. Then when I went to do the x-axis belt, I noticed the x-carriage was upside down. The build instructions don't specify an orientation, but I noticed that there are teeth on one side of the central portion to grip the belt, which means that there IS an orientation. So out went the smooth rods again, then the threaded rods, flipped the x-carriage around, put everything back together, measured, tightened, etc. Then I noticed the zip ties holding the linear bearings had come undone. They just don't grip well enough, no matter how hard I try and torque them down. Any suggestions on brand/kind of ties? The ones included are 2mm, I believe, but clearly cheap ties. I also had trouble getting them tight enough to hold the belt ends together, so I need better ties or some other solution. *sigh* So close, yet so far. Haha
Re: My Replikeo Prusa i3 Rework Build
August 23, 2014 12:32AM
Mike, I've been using the zip ties that came with the kit and some similarly-sized ones from WallyWorld, 100 for $1.29! YMMV.

Bratan, IDK about the MOSFET grounding out but that z-axis stabilizer is similar but Tech2C's is a perfect fit. I printed part of that other one and it didn't line up well for whatever reason. It was easier for me to just use Tech2C's... winking smiley
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