OHAI: Open Hardware Assembly Instructions

1 Gather materials

2x- [HD-BT0049] M5x14 SHCS, Black-Oxide
1x- [HD-BT0225] M5x10 BHCS Stainless Steel
67x- [HD-BT0073] M5x10 BHCS, Black-Oxide
4x- [HD-EX0062] T-Slot Aluminum Extrusion 500mm,Tapped on Both Ends, Black
4x- [HD-EX0086] T-Slot Extrusion, Aluminum, 530mm
8x- [HD-EX0090] 90 degree 2 Hole 20mm Slotted Inside Corner Bracket with Dual Support
1x- [HD-EX0092] 2 Hole Inside Corner Bracket For 20 Series
4x-[ HD-NT0044] Post assembly M5 T-nut
68x- [HD-NT0053] T-Slot Slide in T-nuts for Aluminum Frame, M5
1x- [HD-WA0007] M5 Washer, Steel, Zinc Plated
69x- [HD-WA0040] M5 Washer, Black-Oxide
8x- [PP-FP0152] Corner Bracket
1x- [PP-GP0410] Electronic Chassis Mount-Front
2x- [PP-GP0411] Electronic Chassis Mount-Back
4x- [PP-GP0409] Frame Foot
1x- [AS-PR0011] TAZ6, Tippy Feed Tube Holder with Bushing Assembly
4x- [PP-IS0098] Bed Mount Chassis with Insert
1x- [EL-HR0142] Z Endstop Harness, Assembled
1x- [AS-PR0150] T-Slot dust cover, cut, 285mm
1x- [AS-PR0151] T-Slot Dust cover, cut, 522mm
1x- [AS-PR0137] Spool Arm Assembly
1x- [AS-PR0130] X-End Right Assembly
1x- [AS-PR0164] X End Left, Workhorse

Frame Assembly Palette

2 Prep hardware

Place the t-nuts in the locations according to the drawing.

Back locations

Front locations

3 Load the fixture

Place 2X [HD-EX0062] 500mm extrusions in the vertical slots and 2X [HD-EX0086] 530 extrusions in the horizontal slots.

Loading the fixture

4 Clamp the fixture

To clamp the frame into place, pull the handle towards the extrusions.

Clamping down the frame

5 Align the t-nuts

Utilize the t-nut alignment jig to align the t-nuts in preparation for installing the [PP-FP0152] frame corners.

Aligning t-nuts with jig.

6 Place the corners

Align the 4X [PP-FP0152] frame corners with the t-slot nuts on each corner.

Line up frame corners with t-nuts

7 Snug the corners

Fasten each [HD-FP0152] frame corner to the frame by hand, using 16X [HD-BT0073] M5X10 BHC fasteners.

Fasten frame corners until barely tight

8 Torque the corners

Torque each [HD-BT0073] M5X10 BHC fastener to 40 in*lbs.

Torque down the frame corners

9 Remove the half frame from the fixture

Remove the frame from the jig and repeat for the back face of the final assembly.

Removed from the frame jig

10 Install the internal frame corners

Take one 90 degree corner bracket [HD-EX0090], two M5 x 10 BHCS [HD-BT0073] and two M5 washers [HD-WA0040]. Attach one to each inside corner of the front and rear frame as shown.

Materials

Fastener in place

Fastening

Torquing

11 Assemble frame front

Using two [HD-BT0073] M5x10 BHCS and two [HD-WA0040] M5 black oxide washers, fasten the [PP-GP0409] frame feet to the threaded holes in the bottom of the frame assembly.

Using one [HD-BT0049] M5x14 SHCS and one [HD-WA0040] M5 black oxide washer, fasten the [AS-PR0137] spool arm assembly to the post assembly nut on the photo left side of the frame. This can be left loose at this time.

Using one [HD-BT0073] M5x10 BHCS and one [HD-WA0040] M5 black oxide washer, fasten the [PP-GP0410] front electronics chassis mount to bottom most t-slot nut on the photo right side of the frame.

Use two [HD-BT0158] M5 x 12 BHCS and two [HD-WA0040] M5 washers, attach the [PP-IS0098] Y-Mount Chassis to the frame along with two Thumbscrews [HD-BT0554] with Leashes [PP-GP0448].
The screw used mounting the Y Mount Chassis should be fed through the end of the thumbscrew leash facing the opposite direction of the thumbscrew before being attached to the frame.

Using one [HD-BT0225] M5x10 stainless steel BHCS and one [HD-WA0007] M5 stainless washer, fasten the [HD-EX0092] aluminum corner bracket to the top most t-slot nut on the photo right side of the frame.

gather materials

Spool arm height jig in place

spool arm placed using spool arm height jig

Install frame foot

Install bottom Electronics Case Mount

Install upper Electronics Case Mount

Materials to install Y Chassis Mount

Install chassis mount to lower frame rail as pictured

thread thumbscrew into insert

Materials to install Y Chassis Mount

Install chassis mount to lower frame rail as pictured

thread thumbscrew into insert

Frame front assembled

12 Assemble frame rear

Using two [HD-BT0073] M5x10 BHCS and two [HD-WA0040] M5 black oxide washers, fasten the [PP-GP0409] frame feet to the threaded holes in the bottom of the frame assembly.

Using two [HD-BT0073] M5 x 10 BHCS and two [HD-WA0040] M5 washer, attach the [PP-GP0411] back chassis mount to the frame.

Use two [HD-BT0158] M5 x 12 BHCS and two [HD-WA0040] M5 washers, attach the [PP-IS0098] Y-Mount Chassis to the frame along with two Thumbscrews [HD-BT0554] with Leashes [PP-GP0448].
The screw used mounting the Y Mount Chassis should be fed through the end of the thumbscrew leash facing the opposite direction of the thumbscrew before being attached to the frame.

Use one [HD-BT0049] M5 x 14 SHCS and one [HD-WA0040] M5 washer, attach the feed tube holder [AS-PR0011] to rear frame as pictured.

Take the [EL-HR0142] and place it into the frame extrusions as shown. Use the [AS-PR0150] 285mm dust cover and cover the wires on the left side of the frame. Use the [AS-PR0151] 522mm dust cover and cover the wires on the top of the frame.

gather materials

Install frame foot

install lower Electronics Case Mount

Slide one T-Nut towards the top

Place Molex connector end of Z-Max Harness into shorter section of dust cover

push harness/dust cover into extrusion slot

Z-Max Harness properly in place in extrusion slot

install upper Electronics Case Mount

Insert long portions of Z-Max Harness into longer section of dust cover

Insert harness/dust cover into slot in upper extrusion as pictured

push along dust cover until fully seated at opposite end

Z-Max Harness properly installed

Frame flipped over

Install feed tube holder as pictured

materials to install Y Chassis Mount

Install Y Chassis Mount to lower frame rail

thread thumbscrew into insert

materials to install Y Chassis Mount

install Y Chassis Mount to lower frame rail

thread thumb screw into insert

Frame rear assembled

13 Attach the front frame to x-end motor

Take the front frame piece and lay it so the bottom of the frame is towards the top.

Take the X-End Left [AS-PR0164] and place it on the frame as shown.

Use two [HD-BT0073] M5 x 10 BHCS and two [HD-WA0040] M5 washer, screw the z-upper tho the frame as shown.
Use two M5x10 Flanged Hex Head [HD-BT0250] to attach the z-lower to the frame.

materials

Z-motor end in place

fasteners

this fastener first

then this fastener

required hardware for Z-Lower

fasteners installed

tighten both with wrench

14 Attach the front frame to x-end idler

Take the X-End Idler Assembly [AS-PR0130] and place it on the frame as shown.

Use two [HD-BT0073] M5 x 10 BHCS and two [HD-WA0040] M5 washer and attach the z-upper to the frame.
Use two [HD-BT0250] M5 x 10 Flanged Hex Head to attach the z-lower to the frame.

Place z-end idler

Screws for z-upper

First this one

Then this

Screws for z-lower

screws installed

tighten with wrench

15 Attach back frame to x-ends

Take the assembled back frame and place it onto the x-ends as shown. Do not pinch the wires for the z-max switches when sliding the back frame onto the x-ends.

Use four [HD-BT0073] M5 x 10 BHCS and four [HD-WA0040] M5 washers, and attach the z-uppers to the frame.

Flip the frame over so the screw holes for the z-lowers are facing you.

Use four [HD-BT0250] M5 x 10 Flanged Hex Head to secure the z-lowers to the frame.

Frame back resting atop assembly

Slide frame onto x-ends

DON'T PINCH WIRES

first this fastener

then this fastener

this fastener

then this fastener

frame flipped and rotated on workbench

install this fastener

then this fastener

on the other side, install another fastener here

then install this fastener

16 Place the left Y-Mount Chassis

Use the spacing jig for the left two Y-Mount Chassis [PP-IS0098] to get the proper placement.

Slide the chassis mount against the jig and torque the fastener 5in*lbs

the correct jig to use

Jig in place, loosen chassis mount, press to left against spacer jig and re-tighten

17 Square the frame

The 4 frame feet must be removed for this step

Take the frame to the granite block and check the squareness of the frame. Use a 12" rafter square to check the frame for squareness. The frame must be within 2mm of the rafter scale on either the top or bottom of the square.

Torque all 8 Z-Lower to Frame fasteners [HD-BT0250] to 15in*lbs

Square