josh – Page 3 – JOSH'S MANCAVE LIVE

04/03/202204/03/2022

World Book day fun

So my sons harry potter mad and wanted to dress as harry potter for world book day, long of the short we had lost his harry potter glasses.

So being the creative type and someone who loves to recycle designs I found an old harry potter prop I had designed for photos and decided to make some wooden prop glasses.

I then made the first pair of glasses up by removing the outer cut line and then using a square and weld tool I added some more girth to opposite end of the glasses offset the outer edge by 3mm and then notched it using the vector path edit tool to add 2 reference points and then converted notch to a path. then matched the outer edge of the glasses and made 10 x 100 mm rectangle as I had done a ruff measure of my son’s head. to the top edge, I used a circle tool to make a circle in the top edge of the rectangle then off set it inward by 10 mm to make the downward curve for behind the ear I then added a 10mm square to add some length circle to round off the bottom of the arms using path editor joined all 4 parts together and removed all bits I didn’t need. thin I did an offset inwards and set it to fill. then did a 3 x 5mm rectangle and placed in to cut path and i used the convert to path tool and inserted it in to the path. time for the first cut of the design. forgot to capture the screen of the original design doh.

it worked but was loose as can be on my son so went back in a remixed it a little by shrinking size by 20mm on the arms and smoothing all sharp edges I also made a bridge by using path editor and adding a curve in the middle top and bottom.

back to cutting now fits perfectly one happy boy who had it on all day,

A nice quick one. love the joy of making my boy happy.

30/01/202228/02/2022

CR-10 Upgrades part 6

this has been a bigger build than I first expected around 100 hrs of printing a lot of remixing was involved so some things worked some things I have had to print again and again till correct. think they are all correct now as they fit for me.

As will any project files they are a work in progress. still need to reprint final fixes to test but the current design work with some drilling or being an angel so no rush for me. i would say there are a good few days of printing involved with this project. but well worth it.

So what this part covers:

All in one Cr-10 Remixed for Dual Y-Axis linear rails kit
UPS 12v big tree tech
Filament runout sensor big tree tech
Modifing TFT screen firmware.
Dragon Hotend and issue correction
BISQU Flexplate

All in one Cr-10 Remixed for Dual Y-Axis linear rails kit

This is a remix of this design by Cornely_Cool can find the original design here. you will need these files for some of the builds my remix replaces the front-rear panels front left panel and several of the base plate files. this is a work in progress it works for me as of me writing this blog post.

The link to the files can be found here.

So why am I doing this the original printed mod I built-in part 3 or 4 doesn’t work with the upgraded linear rails so It doesn’t fit so going to make something using an existing design with a remixed twist as its not 100 % right for me due to the dual linear rails and the design wasn’t using SSR and some other bits. First up going to salvage parts and order up some metal work going to raise the machine 60mm and have another 70 hrs of printing ahead of me first up parts. needed some aluminium 2020 and 2040 some connectors to hold it all together some corner plates and some new rubber feet as I disposed of my original feet from my cr10 also have hight clearance is an issue with a shed roof. might still need to lower racking. have also ordered a small 5v 3amp PSU to internally power the pi that’s running the printer. as this is a custom build have also ordered some aviation plugs to tidy up the wiring and install better-suited wiring. I will have a sonsoff switch as master power on and off and use relays to turn on and off power and lights for web camera. I will publish a full shopping list. end of the post when I have calculated what I used and what you will need. will add build of material

Time to start the remix so starting with the base panels going to remix the Mosfet panel as don’t use one as running a silicon heat bed. so will house SSR relay, a 2 channel 5v relay for lights and printer and UPS board if and when it all shows up.

this is done using the panel as a reference and using PCB footprint diagrams have added a 6mm standoff for each part.

will house SSR UPS and 2 channel 5v relay it a work in progress relay fits just only screws fit

Next up I am going to remix the raspberry pi and pi PSU plate as I am going to use a hard-wired PSU 5v 3A so will need to make some mount holes for the PSU but first going to test its powerful enough. as I don’t have a reference diagram going to photograph the underside of the PSU and measure it using it as a reference image. will then trace holes for mount. won’t print it till I have tested PSU. have made some air vents and bars so i can make holes to mount it when it’s done.

the PSU holes are off as on the wrong side but will drill and bolt PSU in place. The final file changed but might be off.

The final modification is to the mainboard fixing plate so used the existing plate as a reference for size then added footprint overlay to trace holes for mounts.

insterted image of board set to size as reffrence

the final hurdle was going to print the massive PSU plate on the cave monster cr-10 but due to wiring snagging I cannot print on it so into Prusa slicer have cut it in 2 will print half and half on both the Prusa so I can do it in half the time will line up and glue the halves together.

Now that I have remixed all required base plates now I am going to centre the middle post I have remixed the font panels to be blank as due to the dual linear kit I cannot fit a front-mounted screen. so going to remake the panels to smaller and more central with a 5mm notch to allow for fixing plates.

Gone for a central notch 5mm deep changed it again since this maid it longer.

Next, up is the power plug panel got to notch this and move the power connector as it’s right in the way of the plate.

slotted for brackets with 5 mm and move power connector by 20mm to the right changed it again as just on the borderline.

The last plate finishes just base plated to finalise. just had to add a hole for cables for the screen

The last panel was modified for screen cables for mounting to the frame.

Time to start printing I am going to run it all in PETG. time for some overnight parts I am going to set my Prusa’s going shame I haven’t reinstalled Octofarm to run this but will do on the next build as will be running 3 printers in it. About 4 days in now all printed apart from pi and PSU mount that’s currently running and some fixing brackets. time to build the base has been tweaked the construction of the metalwork with some extra brackets to make sure this going to the stable with the printer on top of it.

last part on the prusa printing then to assemble it all.

Oh wait fan director last 8hr print that’s overnight parts for as I am already deep in assembly.

last print of base builds overnight parts.

Time to build it.

Time to put it all together for the final time hopefully and I can then put a pin on this machine.

first up assembled outer frame with base runners and corner plates with the feet i have brought. will bolt down the centre rail once I have centred it on the base plates.

now I have a squared base I will add the uprights and bolt them down with the L brackets i have sanded the tabs on the printed walls so starting from 2040 I placed the first part I then added a bit of 2020 in the middle and continued on till all the walls was installed then using 2040 plates i bolted the base to the 2020 uprights. I will add another bracket on top of this to secure the printer to the base.

now on to the base panels, I will place them loose before I add the fixing clips in place.

all my components line up perfectly well almost but still bolts down sold just need to adjust the centres slightly as the footprint diagram I found is wrong on the relay. I am getting better with each project build. now everything is in place have added the clips have bolted down all the components apart from PSU as need to modify it for the upgraded fan.

fitted new PSU base plate but holes are off, needs to modify

Final version the pi & PSU plate is done holes are wrong but I just drilled new ones and screwed it down with some 6mm M3 bolts I will start wiring up tonight.

actually going to need cable management. so time to fire up the Prusa 1 more time for a plate of connectors.

The wiring

First up will run the mains wiring from the 3 pin kettle connector to the Sonoff switch then across the on/off switch for the pi PSU and the main printer PSU. now I have the main power in.

Main power all in forgotten my wifi password so I cannot test the Sonoff all fit perfectly.

Next, I will run negative connections for the 2 channel relay and link the relay to the pi so I can control it via Octoprint. I will then run the positive to the PSU and lights circuit for the web camera. next up are the jumpers from relay to the raspberry pi going to use 5v ground gpio 23 and 24 pins I am also going to use 3.3v and pin 9 ground and pin 14 for a temperature sensor inside the enclosure so I can adjust the fan if it gets too hot inside.

Ok, my worries about the mini PSU and voltage is fine there is no under-voltage which is great as sometimes things are not what they are advertised as.

time to pull out the wiring diagram for the mainboard.

list all connectors as you can see negative and positives are needed on end-stops and thermostats if not get kill alarm so on the end-stops and thermostats square is= to ground.

end stops and motor connecotrs are wired board side got to do some soldering but will cover that later as need to make some new wires for the heat bed and y-axis.

I am actually going to modify one of the front panels to house a Micro sd card reader and a fan speed controller PCB so back into fusion 360 going to add foot block and add 2 3mm holes to mount the front 2 PCB holes as then in the main plate I will add an 8mm hole for the potentiometer. then over the other side of the panel, I am going to cut a hole for the sd card reader to squeeze into I will then fix it with hot glue. as the original design used a USB switch to allow for firmware update the skr board only allows for MicroSD upgrade so as the board is going to be embedded this will allow for firmware upgrades in the future.. this will be a 4 hr print I think. as I test fitted the 2 halves I needed to reprint this anyway as it’s off by 10mm so now will fit perfectly under the front plate support

So out with the callipers, I go to make everything will fit and is sized correctly. time to modify the sketch.

will do an overnight prototype print. well, morning has come and yes everything fits fine just need to screw the PCB down and hot glue the sd card extension in place and we are a bit of sanding for the tabs and should be good to fit. note to self make sure you sand the tabs another 3 hrs print and will defently resand the front panel as snapped a tab these things happen when prototyping but its starting to take shape.

whilst I’m at it going to add 10mm space on the rear power panel as it was very tight prefer there is some wiggle space more airflow as well going print it on ultraviolet tonight back on with the assembly tomorrow.

redesigned as was too tight on the centre spacers.

All panels are now fitted going to cut myself an aviation plug holder jig. so out with a sheet of acrylic time to cut and bolt together.

So over to light burn a sheet of acrylic in the machine let make this design I got off Thingiverse https://www.thingiverse.com/thing:4201220. I have relayed it out slightly different as I want to fit on a sheet of 300×400. if someone wants it will share it.

as I want a good connection going to start with the 4 pins i have given up on the six-pin as NEMA wiring is too fragile.

Not everything you find on Thingiverse is right so had to modify the file slightly to get it to work but now a more compact jig. as the dfx is segmented and didn’t cut right in light burn fixed now and modified the base as was too big for smaller workspace ready to solder tonight. got 1 socket to solder

assembled ready to make my new connectors

Nice and neet now for the heat bed connector need a new connection as the board is about 20cm further than it was originally also my bad soldering means it intermittently doesn’t work. so time for a fresh connector.

time to solder up a new heat bed connector with longer wires so I can wire direct to PSU and solid-state. out with my soldering iron I know the following

Pin 1 = Thermostat Positive if wired wrong alarm will sound on SKR board

Pin 2 = Thermostat Negative if wired wrong alarm will sound on SKR board.

Pin 3 = Heated Bed as 220vac voltage don’t matter which goes to witch

Pin 4 = Heated Bed as 220vac voltage don’t matter which goes to witch

have put continuity meter across the pin and end of the cable and they all check fine

now to wire it all up and we should be good to test.

all ready just need to shorten the neo pixel cable as made it way too long. going to use the bit I chopped the neo pixel wire I will use for the filament run-out sensor cable. Then it’s time to finesse the cable management.

The next issue the fan direction vent is hitting the y axis so going to make my own custom offering so going to find the footprint of 120mm fans going to make it easier to fit low profile fan shrowd. should have space as gone for 35mm high to 19mm high

So should have good clearance space. 6hr print will run tonight need to swap filament as running low on Neon orange.

The wiring list is getting shorter just time consuming getting there.

end stop and motors temperature sensors and relay wiring left before I’m done.

Time to link the raspberry pi to the relay using 5v ground and pins gpio pins 23 and 24.

Temperature sensor installs time so using 3.3v ground and Gpio pin 14 for the probe have added the Dupont connectors to go over the gpio pins going to have to do some changes via rasp-config to let the system know pin 14 is sensor pin. but will check if this is needed or not as it is an old guide I read. I will also need to add a plugin so it will display the internal temperature of the enclosure so I can monitor and adjust the fan speed accordingly.

going to have to change the sensor type as this type I have installed does not have a pull-up resistor on it so just ordered another type off eBay so will swap it out.

Finally, The wiring is now all complete just need to test everything works.

finished all internal wires oh wait missed the lighting circuit Relay.

The camera light relay I have pre-made a cable from the 12v supply the positive will go to the power connector negative will go via the relay so I can switch camera lights on and off when a print starts and ends. have had a change in the design as I’m not using USB switch going to wire power connector to where the switch was going an install an A to A USB panel mount so I can connect the camera to pi externally power will be via the relay so I can turn halo on and off if required, should have parts Monday. as I wired the power socket tonight I had a thought about the USB connection wouldn’t work. back over to fusion 360

Designed the first version it’s printing now but it’s not going to work as needs relief for the screws so have remixed it further and come up with this going to print it so have both options but think this is the winner.

As you can see from original to remix v1 and final v2 these are the things you have to take into account when remixing a project.

In fact, I am going to redesign it again as the cable layout is different so back into fusion I go doing a scrapy print to see if it works but this should be the final design have made a few changes including screw head relife and it fits perfectly added to the remix pack

version 3 with cut out for plug that turned up

this project is pushing my design skill and I love it.

the finished item I do love playing around in 3D print.

Time to fit it all into the machine.

Right, I am on the home straight I need to make some form of protection for the printer’s innards.

going to cut some black acrylic insert them in the middle of 2020 extrusion as dust covers.

so been thinking about how to do this without having to remove the front of the printer going to do some testing. I am going to cut some test bits 20 x 74 mm at a start to see if I can insert it then centre and add a fixing clip to hold it in place I will then make will also design a middle clip that can be removed to gain access. well,

that’s the idea, time to make some test bits. so over to light burn and as I have some offcut left from the jig build going to cut some strips to see what can be inserted,

time to cut some interest to test have labelled them for ease of use

So looking front on Left = 77 middle = 146 right = 75 now to make 2 x 200 long size X plates for each area will then 3D print the customizable design for centre plates then to design some clips that will be after I have the covers fitted.

I have decided to make it a 3d printable version obviously they will be subject to where your cross braces are. but you can customise them in the slicer. i am going to print my covers so they match the base as I could cheat but I want this to be a mostly printable design. also, put a clip together

the first plate is printing

here is the centre plate design will be making left 70mm, 138mm and right 68mm. the centre area 72mm across. total area 100mm

Clip design I have put these in to hold the panels in 3 per panel so 24 in total. currently printing a sheet.

final plates are printing on the printers should have all the dust covers done tonight then I am ready to assemble the 2 parts have hit one minor snag as the end stop bar is skimming the middle plate need to take a few mm off it to get it to work right will think about how I do this might just be a shorter screw and a 10mm off the tube with a hacksaw. No, I own a 3d printer. so now printing a shorter 11mm x 20mm tube and have a shorter screw to fix the issue.

only issue is the centre plate as the end stop bar is clipping it.

All fixed worked like a charm now does not rub on plates and makes contact with the endstop. all plates fitted made a cut out for dust cover so waring was more neat.

dust covers all fitted and wiring from neo pixel hidden also hidden the filament sensor wiring if there’s any interest will publish all the other bits I found on Thingiverse that used to help with the project.

Yay parts from china

Just as I was about to put a pin in this build and post the post I have now received parts from aliexpress so back on to some more upgrades. lol so this will be tomorrow as one PCB to fit and wire and one sensor to attach. and a Flexi plate to stick and fit.

So a new day has dawn going to try wrapping this up today bar printing or tuning.

UPS big tree tech

This should be easy to install one 3 pin plug to the mainboard from the ups and 12v supply just got to figure out where to place the board in the enclosure I think I am going to make some holes and add some standoffs as I did with the 2 channel relay. need to look into firmware changes for its use will cover this at the end of this post.

My fingers are crossed my calculation for the footprint of the board is correct and this just pops in with some m3 screws. Well, I’m too good fits perfectly just got to finish wiring it up.

Make sure that the + & – are wired correctly as will destroy the PCB if wrong they are labelled on the bottom of the PCB then links them to the power input on the mainboard like shown below.

then insert the 3 pin connector and connect to pwr-det on the mainboard and then back to ups PCB and it’s all installed hardware-wise.

Now for firmware changes

There are 2 files you will need to change first is in the feature folder look for powerloss.h

I have changed debut and saved each cmd this will save the last state on the printer if there is a loss of power now over to the Configuration_adv.h search for POWER_LOSS

then uncomment the above this is set up for my printer mainboard so pin number might need changing on your device. and purge and retract might need changing as well.

will compile this after making other changes for the filament runout sensor

Filament runout sensor big tree tech

As I waiting for this to arrive seller sending another one middle of February so instead of moping around the workshop getting ready for it all to arrive.

Ok have found a bracket on Thingiverse I am going to remix it so I can mount the bracket directly to my 2020 so will be adding 2 tabs in Fusion 360 so I make this a reality. first, I am going to import the mesh in and will draw two rectangles using the top face of the bracket I then extruded them by 4.40mm then made a centerline in a sketch and added matching holes time to print

Quick and dirty modification but will work.

I will print it shortly the spikes will print not sure why they ended up there are joys of modifying a mesh

Just waiting on the current print to finish should relay run the farm but need to get neon orange up and running it’s on my list of things to do. it’s a long list as always.

Printed ready to fit when I get the parts. just test fitted will just what I wanted.

As I now have the parts time to fit it all to the frame for real as the sensor has arrived.

hidden all the wiring in the frame with some clips.

Going to connect it to the mainboard E0-STOP port you will have to switch it on in the firmware pin 15 was already selected for filament runout.

Now you will need to turn it on in firmware so in configutation.h

find the following FILAMENT_RUNOUT_SENSOR and uncomment it like below.

Next, scroll down and uncomment the following FILAMENT_MOTION_SENSOR and FILAMENT_RUNOUT_DISTNCE_MM set it to 7

and with that just need to reflash with v5 of the mancave monster firmware on the mainboard and we should be good to go.

My Current Firmware CR-10 BTT E3 mini 2.0 with BTT UPS, BTT Filament runout sensor, BL touch and Neo Pixel 18 pixels installed compiled here if you want the vs code files ask and will happily link it for you.

all components are now installed going to join the 2 printer halves and running initial tests. fingers crossed before I permanently bolt them together. Wiring issue, not a big one negative on neo pixel is the wrong way around not a biggie just taken a photo of the pins.

Mine was the wrong way around so out with crimp tools and time to make it right.

remade the connection so let’s test it again. now seems to all be working.

Homes check bl touch works check hot end heats not working for heat bed erm ok not heating need to check the wiring.

Got a feeling negative is what I meant to pass through the SSR going to go back through my notes.

Was 2 issues had heat bed plugged into the extruder and hot end in the bed and the negative was positive no damage all fires up now and works

Just print the front left panel with a modified hole for screen cables. so going to leave that running overnight, just fitted and perfect so that’s finalised.

One thing i will need to revisit is the relay board but I think that will be done in the future as projects are already way overrun and used lots of PETG I really need to invest in centre callipers they are uber expensive one day shall order some.

Time to modifiy my racking

The next job is lowering the racking so I can fit the new printer on the shelf need to move the spool holders down and then drop the shelf level down by 15 cm approx.

cleared the shelf and now to focus on removing shelf and old wiring as will rehouse the wall-mounted pi down also binning cheep fans as they temperature should never get that great and the nose one of them I producing is bad.

Have managed to drop shelf approx 120 mm have refitted shelf and refitted Prusa’s have moved my pi off the wall and disconnected fan. I shall monitor CPU temp via the plugin.

Now to place the printer in its place well nearly first flash the firmware and cave monster ready for action well nearly as I want to finish off the mods before I set it in place.

TFT Screen firmware configuration

One final tweak I wanna look at is the firmware for the screen as want to disable a few features and rename some descriptions if I can not sure it’s possible. but by the power of google.

first up looking at the config.ini

In order for the TFT, firmware is able to provide all of its functionalities/features, ensure that the following options are enabled in Marlin firmware.

General options:

EEPROM_SETTINGS (in Configuration.h)
BABYSTEPPING (in Configuration_adv.h)
AUTO_REPORT_TEMPERATURES (in Configuration_adv.h)
AUTO_REPORT_POSITION (in Configuration_adv.h)
M115_GEOMETRY_REPORT (in Configuration_adv.h)
M114_DETAIL (in Configuration_adv.h)
REPORT_FAN_CHANGE (in Configuration_adv.h)

Options to support printing from onboard SD:

SDSUPPORT (in Configuration.h)
LONG_FILENAME_HOST_SUPPORT (in Configuration_adv.h)
AUTO_REPORT_SD_STATUS (in Configuration_adv.h)
SDCARD_CONNECTION ONBOARD (in Configuration_adv.h)

Options to support dialogue with host:

EMERGENCY_PARSER (in Configuration_adv.h)
SERIAL_FLOAT_PRECISION 4 (in Configuration_adv.h)
HOST_ACTION_COMMANDS (in Configuration_adv.h)
HOST_PROMPT_SUPPORT (in Configuration_adv.h)

Options to support M600 with host & (Un)Load menu:

Options to support dialogue with the host (as a prerequisite)

NOZZLE_PARK_FEATURE (in Configuration.h)
ADVANCED_PAUSE_FEATURE (in Configuration_adv.h)
PARK_HEAD_ON_PAUSE (in Configuration_adv.h)
FILAMENT_LOAD_UNLOAD_GCODES (in Configuration_adv.h)

Options to fully support the Bed Leveling menu:

Z_MIN_PROBE_REPEATABILITY_TEST (in Configuration.h)
G26_MESH_VALIDATION (in Configuration.h)

I didn’t use this as couldn’t get to compile I will revisit this

Z_STEPPER_AUTO_ALIGN (in Configuration_adv.h)

so that’s the merlin firmware now done not to look at the config.ini.

custom logo

so lots of settings and functions here have changed a handful of colours and the way it talks to octoprint.

next up going to look at the actual firmware pre-compiled so I can see what changes can be made. that will be a separate blog post I have added a new icon set and flashed the screen with new firmware to see if it helps.

Dragon Hotend and issue correction

K decided I would go the full whole hog and upgrade the hot end as well. as I wanna look at the movement in the x carriage on the extruder bracket. I also why it is quite tight on the belt.

Issue 1

I fixed it was the hole the direct-drive bracket is bigger than the m5 to linear rail bolt hole so have used 2 countersunk screws to centre the bracket. works well,

Fitted the dragon

I have removed the old OEM hot end. 2 screws and that’s gone now to fit the dragon hot end using Capricorn petg tube between it and the direct drive all fitted now to put the hot end back together upgrade is done. but not quite right cannot get filament into hot end tubes not quite long enough so time to order a length of it so I can get this right.

Issue 2

I noticed there is a lot of friction on the belt so I am going to swap the pully end around as I want this to be smooth and can align the pully across the beam. 4 front screws removed. pully off and rotated now to put the machine back together much smoother think I have fixed it might need a slight tweak but let home the machine and see what happens.

just going to make a benchy test. before I fit the new flexplate.

running into issues with filament sensor the hot end now clogged got a feeling the Capricorn tubes melted so I am going to strip down the hot end tonight and have a look and see if it’s down to that as removed nozzle and still cannot get the filament to come through. have ordered a back up hot end the big tree tech v6 hot end and a fixing bracket as a backup as got a feeling this isn’t right.

will disable the runout sensor for the calibration as I have a feeling it’s thinking it’s a clog on the hot end even though there is now a clog.

removed hot and cleaned and the issue blockage in the tube put it back together loaded it ran 20mm through it and bam blocked again so might be my filaments shit or the tolerances of the tube is too tight might try a different batch and see if I get any joy other wire going to revert back to my back up but that’s going to delay first print. by 3 weeks but going to launch this part of the build and then come back when it’s all printing right. at least makes me know that the runout sensor working. so will re-enable it after I have a calibrated machine.

going to first install the flex plate whilst i figure this out.

BISQU Flexplate

This is something I love on my Prusa printers will hopefully be the same experience. so to install going to need to stick the magnetic sticker to the glass bed.

so have turned over the glass sheet and cleaned it using isopropyl now to apply the sticker sheet went down will not be 100% straight but no one will notice.

before I test the plate on top. going start by resetting the EEPROM and then going through calibration again as don’t want to mess the sheet up. but that will be in part 7

all fitted now a waiting game for the new hot end so will leave this here final part will be testing it all out.

21/01/202230/01/2022

CR-10 Upgrades part 5

A happy New year to you all, Incoming parts have arrived so time to finish off this project last 6 upgrades firmware recompile and hopefully will be all done.

Y-Axis Linear rail upgrade
Neopixel install

Y-Axis Linear rail upgrade

You can get the kit I used here.

Yay The kit arrived when I was away so a bag of bolts and t-nuts aluminium end plates and base plates.

this is going to evolve some guesswork as with all china kits they never provide any instructions but basically will fit the 2 cross braces and add the rails to both and bolt them down will leave the supports lose so I can make sure all is plumb and attached the bed this is in theory fingers crossed.

Wow, they are tight going to loosen the frame ok now to centre them as best as I can. Now that I have the 2 cross members installed loosely to add the linear rails and 18 nuts and bolts on each rail to bolt them down lining them on the cross brace.

Now to mount the bed to the rails start with one side front bottom placing aluminium spacer and 30mm bot I fix in place I can see the left is off so nudge them to line up so I can put a bolt now to install the remaining 14 spacers and nuts. bed or carriage is attached I check it for lateral movement nice and smooth so I reattach the belts and repeat can that the top needs to come over. now I have it centred time to tighten everything up oh then looked at reference images of add noticed as i had 3 bits left that i couldn’t identify.

They are to make contact with the end stop. so add them now to install the rail end plates so another 8 screws and t-nuts. 4 aluminium covers later it’s done

Now waiting on spacers for the bed as I manage to lose once so should have them Friday also chatting with the vendor as my big tree tech package has gone missing in my absence. below is a montage of what happened through the build.

Neopixel install

Bit of 3d printing have found a led tape mount that I have modified to fit the gantry perfectly I am currently printing the bars in 2 parts will then print the end caps. 3 hrs later will just do a test fit tonight. ok, the first attempt failed so going to print into parts and have gone for a solid infill to reduce the movements see how it turns out. the bit that did print fitted though.

failed again argh going to look at slowing the print down to see if I can get it to complete

attempt number 3 with a raft this time let’s see if these thin columns will print.

So added a raft fingers crossed. Update 50% done still holding.

I miss calculated the length going to use a failure so sort it so chopping down a failure bit. also need to get a heat gun on it to take away the stringing.

made a mall 30mm section out failed parts and put 12v thought it to see if it lights and it did now to finish the cable.

right, this is going to be a bit of guesswork I will need to see how it pans out as I have changed my mind on how I am going to set it up but from what I can see I will need a 1000u competitor and 330k ohm resistor the competitor will go between ground and live and the resistor will go in line with data wire. I will make a 3 pin JST Xh connector so I can plug it into the mainboard this is the simple part. to install it I am going to stick the 18 LEDs to the top bar of the printer and stick it the v slot or I might stick it to some insert clips I have found that will allow me to stick it to it. still toying with this as I type this post. now the firmware is where I am going to start asking more questions as no one seems to be able to answer my questions. argh, have contacted support as they all seem to be for an earlier version of marlin firmware see what they come back with.

Figured I all out myself and was it a fucker so bugfix changes layout you will need to go ini folder in vs code fetures.ini and then change the following. go to adafruit comment on neopixle_led change to the following. NEOPIXEL_LED = https://github.com/CommandoreBombardiero/Adafruit_NeoPixel as shown below.

Now go configuration.h and search NEOPIXEL then change like below.

Then build it will fail with something about the delay so then go find Adafuit_neopixle@src- some numbers and letters you will need to change the location in the brackets to the location of your delay.h file in marlin/hal/shared/delay.h can see it for my dropbox location below.

build it again might fail but then if you build one more time success, wow my mind is numb now only taken the best part of 3 weeks on and off to get this to compile now to make and add connectors and hopefully, it works.

Next, up now I have it compiling is to make up a 3 pin plug so looking at pinout i know i will need a 3 pin JST connector and 3 crimps and JST crimping tool this is fiddly could also be done with Dupont connectors if you didn’t have JST ones kicking around.

Time to update the firmware wish me luck. sd card in hand. a bit nervous lol.

hmm, not working I am not sure if it’s the wire or something else going to check through my notes and see if it’s something like the wrong controller pin or it’s tested the wiring and got a continuity check on negative and positive.

checked over the firmware code and had assigned the driver pin as 4 instead of PA8 will flash the firmware again v4 I change the version number each time I make changes to the code.

Now to put every thing back together and add some cable managment an figure out a way to mount the unit to botom of the printer well untill i figure out my next mod more on that in part 6. will also need to re calibrate the first layer again hoping for the last time.

Once dialed in going to start running parts for the next modifcation going to take a few weeks to get bits in from china and ooznest also got to rework some bits as well. going to do the rework first before spending out on parts. as all these mods hav spireled out of control.

Next steps

When the bits turn up from china I need to enable filament runout sensor and power loss in the firmware but that’s a lot more strait forward.

Will make changes to config.ini for the screen when get the new bits as will allow the main board and Octoprint to communicate with filament runout sensor as that’s where its plugged in.

We’ll all short lived control box don’t fit under machine to going to make something better see part 6

19/01/202219/01/2022

Wishing all my readers a happy new year

I know it’s a little late but been ruff Christmas for my family. back now with more fun projects going to add to my modular shelve as my secret Santa came through with the bits, I asked for. part five of mods I being slimmed back as i am missing parts from china will add them as they arrive in part 6. that’s if part 5 all tests work well. as having an issue with part 4 that requires fixing. looks like a bad solder joint. on the aviation plug so made a jig to help solder it.

I am also considering making all in one jobs using a remixed version of designs on Thingiverse but working it all out now.

sneak preview of how the printer is looking atm. more to follow when amazon deliver missing parts today

10/01/202210/01/2022

Modular shelving for 17 ml airbrush model paint and 65mm wiring spools and 200 ml thinners bottles.

so like all my ideas I am sitting in the workshop looking at how to reorganise my paints and small wiring loom’s. So I have a little wall space left and my model paint collection taking up 3 draws on my dump bin wall. so howto free some space.

so out with callipers and measure up some bits bottle dimensions and then over to light burn and make a quick sketch before I export it over to fusion why light burn I don’t have a copy of AutoCAD anymore I don’t have the finance to get one. the sketch is in 2d as you can see below after its imported dxf file into fusion 360.

From 2d to 3d is just a simple job of extruding parts so the base if -5mm then the part holder is +10mm then I add +20mm, paint holders with wire holder I have created a c pattern I extruded the whole thing +60m then find the centre point for the hole and insert cutout 20mm as I know my pipe I’m going to use..

I then added 5mm wall mounting holes to the centre point of the horizontal and jobs a good one still need to design a spool holder for wiring but that’s a 20mm tube I have kicking around.

away we go in petg for the 17ml bottles holder shelf.

airbrush paint holder is done very happy with it.

I will try the wire spool holder next as already have some spool ends for the 20mm pipe I’m using just going to test it fits the spool before I commit to print. also added holes for the wire to poke through and be ready for print. the 20mm fits like a glove.

Right after the success of my airbrush paint holder going to print with wire holder time to try my mini wire spools

overnight parts and came out perfectly have cut down some 20mm duct pipe to fit.

I am going to quickly design some spacers for the spools and remix some end caps for the project as the concept works just will make it easier to assemble it’s looking good so far

test fitted and all fits got make some spacers.

the printer is busy doing the 200ml bottle shelf so afterwards will run the spacers and put it all together.

The bottle shelf works well too so will put all 3 designs up on Thingiverse later

might add a new design for resin dye as draw full of that as well to store

now to test spacer washers for the wire see if that works need to print 2 more shelves I will do this overnight I think. first, some tweaks Right inner spacers need to be fatter going to test 2mm in width but that’s the only improvement I think I need to make.

new 2mm spacers fitted ready to find some wall space. printed a second one for the rest of my wire

Much better fit with bigger spacers.

So the modular shelves are born. I am sure i will be adding to the collection as hoping my secret sainter has come through as have two nail polish remover bottles coming my way. well as apparently they are good for isopropanol alcohol and nail varnish remover dispensing as i use loads on cleaning things and a better way to waste less. so can see an added design or more as I find new ways to space save in the workshop..

You can find the design up on thingivers. will do a video of me playing around with fusion 360 as a lot of it is experimental as I was taught in 2d and still learning 3d and CNC just finding the time to have a day playing with family and day jobs sometimes is hard. but i love it.

30/12/202131/12/2021

CR-10 Upgrades part 4

So this is all going to be 3d printed mods I have already done a 35hr print on the control board side I have printed the new feet need to print the SSR module clip might set that up whilst I am remote in wales the joys of being connected. so all I will need to do is 2 lids then will be ready for the pro upgrade.

also mounting on the screen on the side of the machine. might need to reprint the printing bracket. as want it on the left-hand side of the machine.

23hrs of printing done should be finished by the end of the day,

so just uploaded it to the local computer and now have kicked off the amazingly long 23min print haha so will only be 2 x 7hr prints left when I get home on Monday. just as I feared the small print it failed never mind noticed and cancelled the print. will check back with the main print later.

80hrs combined printing still a little cleaning to be done

wow, that’s the long prints done now for some smaller prints and armed with elnet the king of hair spray when it comes to getting prints to stick well. as Pritt stick is too messy. wow just saw the bend in the heat bed how did that happen bent it flat again. just going to adust the bed by probe till it’s nearly on the money then I might lock tight them in position for the moment. probably should have done that before I kicked off an 8hr print.

I will be going over to a flexible steel bed soon but till then I am going to continue on the old fashion way well till the credit card bill rolls and I then have my monthly spending pot.

lids and SSR printed and that just under 1kg of filament was done. on the case.

so time to strip out the old box and fit the electronics in the new one oh and to add the new feet so it will fit.

just need to order some silent fans as the control box fan is really annoyingly loud so I have orderd 120mm nocturia fan and I think i will need to order 80mm one for the PSU supply. I will be opening that up in the rebuild as one i dont know its voltage and 2 pin numbers 2 or 3 so will order that when i konw.. I then have to think about speed control as i don’t think they need 100% speed but that I will be looking into as we go, as going to monitor temprature with a probe in the electronics low voltage box.

Have been thinking about a name for my cr-10 modified machine that came up with cave monster. so the next round of modifications to the code will include a name change haha. will attempt to design him a logo as well for the boot screen.

as i have been spending alot of time getting everything printed for the next step i have been customising my octoprint layout and feel. also on christmas crafting for friends and family so yes been a fun week that and i am re jigging the work shop as need to add storage for extra tools as need to make it all work.

High voltage side.

time to look at power supply and lable up wring before i strip it out the box. next up power input and switch. I will be making new wiring for all power elements. First up adding the mains power plug and switch. looks like the are going to need a little help fitting so out with the dremal and they now fit. as it cold have stopped halfway through the job as working how and where to route the wiring and fit the ssr to the psu.

Also, going to wire the printer PSU through a 5v relay so i can turn the printer on and off through the raspberry pi cover this in the Low voltage side of the board but will cover that later.

Low voltatge side.

Now i have the power run across the board I will either add the bucks converter to step the 12v down to 5v to run the raspberry pi or I will use a mains adapter this will allow me to shut down the printer where as the other way would be a total power off. whilst I think I will install the pi and the main control board. am then going to install 2-way relay board so i can switch on/off the machine and lights via the relay.

Time to connect all the power wires and the heater wiring to the board and the SSR.

Now to add all the board inputs and output so end stops motors and sensor

next, it is time to fit the 120mm fan to keep things cool as its a 4 pin I will only use the 12v supply as should work will test this theory later also waiting on t-nuts so I can bolt this to the frame should have them later on today so will finish wiring ready to bolt it all together.

got one more print to go on as adding halo light to the camera so I can film all the loverly creations that I am making with the printer but that will be done once I have installed the rest of the electronics. going to make the camera mount a little more sensible as i feared there’s a little bit of a wobble when running.

testing halo /focus mount is not 100% right but fits and works soldered some longer wiring i will be

As I am waiting on parts as amazon let me down I will be getting the last bits sorted ready to bolt the boxes to the bottom of the printer. ok been a week had a family issue that’s now come to a sad conclusion. so back in London will try wrapping this stage up by Xmas but see what happens.

How my plans have changed

its been 2 weeks of hell over Xmas father in law passed away suddenly so was in wales for a week then came back to london and wife and son both have covid so stuck in london in the house i am negtive and they are both ok.

bad new but good news been working on the project and ironing out my kinks with it so where to start

It dont fit under my printer bed like its ment to due to my custom bed so instead of having a hissy fit throw 70 hrs printing. I am going to let be and will figure it out as i go i have welded the 2 sides together with some high strength glue and exsellitator now bonded together

i then have added some custom stand offs for the fan speed controler and 2 channel relay. i then drilled holes for external raspberry pi power and for fan controler knob. oh and power connector for the halo.

bit of wiring changes to the printer can be powerd off and on by the raspberry pi also using the 12v psu to power the halo light as well also had to change the wiring.

and we are good to go i am waiting on the next mods to show up from the far east got one PCB board still to fit so before i bolt it back together and start testing the new fetures

ready for install just power headers for the pi and add USB PCB when it gets here.

I will leave this here. get ready to part 5 this will be the final part i hope. so whats coming well a UPS 12v board from big tree tech. New fexable bed for the machine and fliminet runout sensor from big tree tech and upgraded linier rail upgrade and thats it.

i think after that i have run out of mods.

see you all in part 5.

03/12/202131/12/2021

CR-10 Upgrades part 3

Well as I await parts I will be working on a few issues and also designing some parts.

What I did not mention in the last part is I managed to drop the control box moving the printer back into the cave as it’s so big and the doorway is so tight. it is back in the cave no so I need to do a strip down and see what’s making my Y-axis go in reverse.

I have a feeling it’s damaged cable or end stop both are on order so should start on this shortly as really thought I had come to the end of the update journey. But no it’s become a paperweight well hopefully not for much longer.

So in part 3 plan is as follow.

Fix reversed Y-Axis after drop
Time to invstigate whilst i wait for new bracket
Fit proper X-axis linear rail bracket.
Reinstall hotend with direct drive & Install new hotend part cooler mod
Print a camera mount:

Fixing the reversed Y-axis:

this was working right till the control box that was balancing on the bed fell off and dangled. now the printer when homing goes in reverse. very odd I have ordered a new wiring loom and end switch. going to start by swapping the bent up end stop. that main pull was on and replace y loom fingers crossed. The end stop has arrived going to fit it now and see if that fixes the issues. If not back to waiting for the loom.

Looms arrived was the Y-Axis end stop wiring has broken out with the old in with the new.

Installing the updated motor mount and bed upgrade:

After ruling that wouldn’t fit the mods and I didn’t think they would fit.

I changed my mind and thought what’s the worst that could happen? So have fitted both the bed wasn’t too bad once I had lined up the centrical nuts up. I then added the new motor mount this wasn’t as much fun, as mounting it needed some parts that were not included. fist up need M5 T-Nuts luckily I had some, countersunk m5 screws again luckily I had these. right now to reattach the Y-Belt to the motor and the bed. for F#&k sake the belt is 100mm too short. looked through my draw of printer parts and spotted gt2 belts was a loop cut i and then rethreaded the bed. ok no to reattaching the end stop it wouldn’t fit as the holes in the bracket are for the raw small micro switch so have mounted the original end stop back in place if this causes issues can modify the end stop to fit on the brackets with old bent up microswitch scavenged for bits let us see hopefully not but have a backup plan.

all back together and homes ok so now for the next part of the project.

Time to invstigate whilst i wait for new bracket:

Now that I have a working printer going to do some more testing to see why it’s not printing right.

ski jump did hit camera mount im testing for later. bars hav foiled my install idea.

right has put a spirit level and my z was out slightly so have adjusted one of the rods. and the new result is better but still off. Hoping on the bracket to sort this out a bit better.

Just waiting on the arrival of the X-Axis bracket now as I am sure there that that is also compounding this. So as you might have figured I am doing other bits whilst I wait and updating this post as I go. Hoping by the end this will be an awesome printer.

The bracket is in the UK just waiting on delivery so probably in 48hrs time. so time to strip off The offending bracket and strip down the hot end ready for the new bracket to arrive

Fit proper X-axis linear rail bracket.

Out with the v2 bracket as there’s a 5mm difference between the centres. as you can see I have removed the modified direct drive hot end as I think this is also the issue with print being fine on one side and in the bed on the other. time to add the bracket and fit the 2 screws. before moving on to the hot end and direct drive. it fits but!! mgn9 rails kit not 12 argh never mind ordered new rail so will sort this out next week.

Reinstall hotend with direct drive & Install new hotend part cooler mod.

I have repopulated the direct-drive motor I have rotated the motor for cleaner wire management. I will now reattach the hot end and fit the modified parts and hot end cooler as it uses existing fans and screws. I had to get my craft knife on it to make it fit but fits fine

I have reattached the BL Touch need to measure the offset form probe to the sensor in the x-axis its -41 and in the y axis, it – 5 so will need to recompile merlin to get it working to make a note of the setting for later. I am already going to need to do this when I add other functions to the board that i will cover in the next post,

Ok next issue

just did a test moving the extruder head to make sure it homes ok and there is a bolt head hitting the z-axis bracket so I have solved this by swapping it for a button head bolt that now makes contact with the end stop so homes fine.

Right, let’s run a bed visualizer scan and see how it is now.

So out with the solid mounts and I think i will be adding back the springs if i can find them if not will order a set and go back to configuring it manualy.

So back to my box labled printer parts to see what i can find as i have a feeling i saved my springs. YES I did saveI them so will fit them going to to look for some nylock adjustment wheels on thingivers so i can lock them in possition

me being me put the springs back in and spent a hour getting bed as flat as i could before i set saving the mesh and dong the z offset.

Time to print a camera mount:

I am using a c270 Logitec camera as I do on all my printers as nice and cheap. doh printed the wrong parts need to find another fixing bracket as printed vertical mount instead of horizontal one never mind. Just a few more hours and then will cannibalise a second-hand c270 that I have ordered so inserted about £24 on amazon and got it for £13.

I have used this one before and it worked well so I pre-printed this design that can be found here. All you will need is some m4 nuts bolts and 4 t-nuts is fixed to the framework like so.

ok, it’s probably going to vibrate like a bitch but I’m game for a laugh lol.

Right now up to date with all mods, there are more to come but going to make sure I have a functioning printer before I go splash out on any more parts.

Calibrate and do some calibration prints without issue,

Now that all is working let’s start to play with calibrating the machine and getting it all working right. so first up is a bed levelling program not sure if I need to run this at the start of the print each time. can make it fewer touchpoints and then to calibrate z offset height.

Still needs a bit of a tweak I think will do a few more adjustments to the springs to get it just a slight bit more level as seems beds off a slight bit. I now remember the pain of manual bed levelling but hope it will be worth it.

made some firmware tweaks let see if this fixes the machine. getting there nearly dialled in just got to drop the head a few 0.01s and we should be good for a benchy test.

All sliced up ready to print think that will be tomorrow

Success i have a printed bentchy will be looking at it properly when i get home later.

so got home had had 1 layer shift so have tightened up the belt and run the print again. now yay had a filament jam and a tangle that made the print fail halfway through so I have decided to 1 make a better spool holder for the printer and 2 go back to sold standoffs or silicon ones so some play but can be locked in a level position.

so whilst I wait for parts again printing spool holder.

It all looks like a good time to print something bigger before I try doing 1 day 12hr prints on it.

eureka is all working well now to do some calibration prints to make sure all is well in 3d printing land.

so after 5 calibration cubes and a benchy or 2 or 3, I think I am nearly bang on as level as I will get it with a bl touch across the bed.

Conclusion to part 3

Now that I have a working machine I am going to turn it into a pro by losing the control box.

don’t worry this will be part 4 as having a working printer that’s improved the prints and has improved the quite ness of the machine, not the control box but that will be part 4.

but back to the big print

well, about 2 hrs in and it’s printed 2 layers a little bit of stringing but let’s see going to risk leaving it alone for 2 hr or more. ok came back 6hrs later and yes it’s still working I am amazed my self oh well 1 day 3 hrs left on the print.

Morning all well been printing for 23 hrs now and still going a strong slight bit of warping not bad and won’t affect the massive print this is side 1 of 2. Apparently, 23 hrs to go but it’s 61% complete so I think it will be less.

Happy the machine is working right so will show the finished side a put a pin in part 3 get ready for part 4 more modifications coming up going to order Y linear rail upgrade so we can start speed testing.

35hrs 10 mins and she is done this is pcb side low voltage.

right, this is the end of part 3 as 35 hr print is complete and looks great. did thteh enw feet over night and now doing the rigth hand side so another 35hr print.

then wehen i get back from wales i will print the lids, and start adding the electronics.

but thats going to be part 4 over all its working well so let see how we go now 1% in to next large print.

Part 4 will be all the 3d printed parts and part 5 is going to be the linear rail conversion on the y-axis.

next post in the next week or so.

01/11/202101/11/2021

CR-10 Upgrades part 2

back on with the updates to the CR10 v1

so where we left off printer moved home and levelled then failed so in this exciting chapter going to strip out the control box and add a new brain to the system.

so as I am upgrading the brain I might as well do some more mods so a colour touch screen is included in the kit. so will be adding that as well. I have been watching a few videos on compiling merlin. so have downloaded the nightly bug fix and will talk through compiling later on.

so time to jump back in there. as I have one working printer at the moment I am going to start off with printing the new screen holder as going to lose the control box completely. these things take up space.

so over to Thingiverse and found this Slim and Elegant BTT TFT35 E3 V3 dual-mode touch screen Extrusion Mount see the link here.

Over to Prusa slicer sliced and uploaded to ultraviolet. as neon orange is offline.

away we go will check back in 9hrs time

9 hrs later one screen adapter is done

some M3 screws later and it’s ready to wire lol ok I forgot to take the screen protector off never mind let’s get it all working first.

one part is ready to install some m4 bolts and t-nuts and will fit onto the frame.

I will print the pro enclosure once I have the printer working online as the cr-10 is the only printer big enough to print it. will print all small parts whilst I get the cr-10 working.

have tried the y motor mount and dont fit right so abandoning this upgrade for the time being. now to do some compiling

Compiling merlin for the first time.

This is sort of new for me as in have flashed my old original cr-10 board before using Arduino ISP programmer and source code. but now it’s all moved over to the Microsoft VScode environment so much easier to do. as the cr-10 has a pre-built config file it’s for the new SKR E3 mini v2.0 BigTreeTech mainboard that’s repacing the stock board.

so you are going to first up need to install VSCode / PlatformIO programming environment. there are plenty of guides on this. once done you will need to head over to https://marlinfw.org/meta/download/ and grab the latest bugfix file you will then find a link in the config folder for the example zip this houses the configuration.h and configration.adv.h files and boot screen files you will need to drag these into the marlin main folder.

open the project in vs code.

in my case I am installing bl touch so needed to change settings to include bltouch and safe z home, also added about probe offset and a handful of other bit. There are vidoes on this so i wont try explaning it all.

I then selected my board type in the core settings. and built it. after the compile was done I found location firmware.bin and copied it to sd card to flash the mainboard. you will need to power on the machine and it should all be ready with the new firmware. will test this along with the new screen shortly same applies for that can be custom-built or you can just use stock firmware.

Now whilst doing my research for this project. I saw the filament run-out sensor porton the new screen so going to use my filament sensor from my old ezout board as it’s compatible.

I am also going to use neopixle function as well so have ordered 1m of led tape. will be experimenting with this soon as I will need to recompile the firmware to use the function actualy will turn it on now and play later time to do some more reserch as wont complie needs some addtional settings will do them first before first switch on as then when i assemble the board i will be able to playwith it will runn cable ready for it so all in place for when the tape arrives

I am also going to name the machine so i know its talke the frimware before i start testing.

now to upgrade the components.

So out with the old in with the new:

so toime to take the old board out

wiring all swapped over wiring to the new board so that it’s ready for its new firmware. whilst I’m doing this have also fitted the final part of the last lot of upgrades to the machine. new motor bracket fitted.

Time to switch it all on

Time for the initial turn on with new screen fitted in enclosure hole as till I have finished off the new mounting box for the machine won’t mount it till then.

turns on lights up and turns off ok a little bit of googling figured out the issue because i have bltouch wiring plugged incorrectly.

now I can see I have messed up the screen with an improper firmware update. long and short of it don’t copy the update to the sd folder to the TFT screen.

Dont copy over the file saying copy to sd.

only copy theme folder content TFT model number and config.ini and just like that is fixed now to flash the firmware I have compiled with fully bltouch customise on. all done did have a message that bed mesh couldn’t be found but after running bed levelling got a saved to eprom message and that’s resolved that.

wow, it’s so quiet moving around the printer all I can hear is the noisy control box on my list of things to modify.

Ready to print have done my z offset wish me luck.

nozzles hit temp beds not heating up time to check connections. brb. ok after checking all connectors and solder joints i have done over the years was poles on the SSR some how got switched now heating like a champ.

My first print failed as need to watch a video how to do z offset done right as was about 4mm off the plate but on a realy grate side it works it runs were its ment to. so very happy. watched a video all of the menus have changed but i think i have got it just going to start a test print before i move the machine back to the man cave.

bed seamms very off not sure if its down to my bracket modification.going to look for the bracket set only as then will save money on getting this sorted time for a evening of reserch fingers crossed i can solve this i am going to put this down to my mod of the braket

So have found braket correct x axis braket and orderd it and a new braket 10 to 15 days i will hopfuly be finishing this project. as i am waiting for parts i will do some other mods then leve part 2 here and come back with part 3 when the parts arrive.

Time to print some Upgrades whilst i am waiting on parts

As my wirings got heavier going to print a drag chain to sort that out so overnight parts on the Prusa will report back in the monring.

all done ready to fit. had a near miss with 2 clips shakeing loose. but it servived the nite.

lets see if it works.

It sort of works but is a little weak for my likeing i am going design my own chain holders for the liniear ralil mount and were the old exstruder motor used to be to use with some stock chain. got to free spome space up from my drive as fusion isnt working,

Hot end part cooler

been looking over thingivers for other mods i can install on my machine as you know me with this ever elvolving project. so as i have direct drive installed i am limeted with hot end cooling mods as i know the stock one is less than great so i have found one that i think will fit so time for another 7hr print. going with the AJS hero v2s as it has bl touch mount and uses factory stock screws so should fit.

morning time and all cleaneed up very well will be stripping offending bracket later in the week from the machine and install new one wilst i wait for x-axis braket that is alreay shipped from china.

test fit with new braket and have removed 5mm off the top corner with a dremal saw bit. Now a nice snug fit with out interfering with the bracket or hotend.

just got a ghost trap to build for the boy before i get on to stripping down the hote end and removing it ready for the new liniear rails bracket that is shipped already so 10 to 15 days time the project will resume.

18/10/202119/01/2022

Taking a Broken CR-10 printer and throwing upgrades at it. Part 1

Will it improve its printing ability? or will it be an expensive mistake?

This project is going to kill or make my CR10 v1. The story so far :

2017 Received the machine from Aliexpress Creality store.

IT worked out the box did some big prints suffered from ringing kept vibrating off level suffered form glitches and so the story begins

brought the duel z modification less ringing started to get the hump with the board shaking the leaving screws lose. so decided to get the EZABL prob kit brought it got it all set up worked great had a major meltdown and destroyed itself with mass blob filament could not unclog it so I brought a complete extruder. took months to arrive. I disassembled the machine and put it in the attic.

meanwhile, I kept on using the Prusa mk2 that I keep on upgrading to the latest spec so forgot about the cr10.

Lockdown happened health workers needed PPE to save lives I joined a group of people making ppe. I started my print farm going 2 Prusa around the clock pumped out face masks ruffly printing 25 masks a day. but wanted to help more

brainwave I got that cr10 in the attic I can fix it as now 100 times more confident with repairing machines. So fixed the cr10 added silicon bed heater with SSR 1 good print out of my machine then for some reason the bed temp was reading very high in the 800c back in the attic went for another year have moved all business servers in the house so needed the space back so brought the cr 10 back down and put it in the workshop,

since then I have sworn at it a lot as keep tripping over and finally decided enough was enough swapped thermistor as thought that was the issue. it was but wasn’t, I finally figured out that it was the gunked connector in the control box that was that actual issue. fixed it after soldering a new connector into the plug on the box.

After a binge on Ali express and some more local parts, I’m going to modify the F#%k out of it and hopefully not go down in flames.

Let’s get this done.

I am going to lose the EZabl probe as has intermittent issues and the upgrade to a BL touch will mean that the EZout is no longer needed.

So thanks to the 3dprintingkid. I have been armed with a brand new ender pro 1.1.4 mainboard which I will be flashing with the BL Touch upgrade kit and latest Creality firmware. It’s already been flashed with a merlin 2.0x but going to go with the Crealitys version for the time being to see how it performs. if not will make my own compiled version.

So I will then have hopefully reliable levelling probe. next, I will be losing the Boden tube extruder for a direct dual drive upgrade off amazon with some belt tensioners being installed and proper z-axis motor mounts aluminium. I am going to upgrade the 8mm rods with some proper anti-backlash nuts.

Then it will give it a test whilst I wait for the next batch of upgrades to arrive from china within 10 days according to aliexpress.

So we are going to get a custom bed chassis, with an Upgraded Y-axis motor bracket.

then I will upgrade X-axis and Z-axis with a linear rails upgrade kit.

Finally, on to the frame, I will fit a stiffening kit and adjustable z rod holders with bearings.

Well, that’s the modification of the parts done. if they all work will be time to do some 3d printed upgrades.

Time to start.

Time to strip the machine down and swap out the old mainboard ready for the flash update. so first of all I have swapped over the cables and connectors from one board to another.

now to remove the old board from the machine. now to bolt the new board in the machine.

I will also loosen the y and x-axis belts and remove idlers ready for new ones. then will remove the extruder and extruder motor and PETG tubing. So I will be ready for the parts to arrive tomorrow.

A new day and a bit of a build ahead well once Amazon has delivered.

Got the first batch of updates,

First up going to replace Y-axis tensioner with nice solid construction easy to fit.

next up time to install the new extruder drirect drive kit.

Right next up to add the X-axis tensioner again solid construction the supplied screws are too long luckily had some M4 x 10mm screws kicking around nice snug fit.

Going to change the motor mounts as they are easier to fit 4 screws each and done much neater.

I installed a clone bltouch that didn’t work very well have been waiting on parts to continue the project. kept on crashing into the bed so ordered the official one from Creality

a week on and have most of the upgrades so now time to fit them all first up going to do the x-axis with linear rails. you can find the kit here have to take off my newly installed extruder and add the new rails.

That was very easy to do next up is the bracket on the extruder. it doesn’t fit what the F%&k I ordered the cr-10 v2 must have a different head on it. time to modify and make it work! if not will have to bite the bullet and order the correct one so out with my needle files and time to lengthen the hole. well 30 mins later now fits. but then the probe mounts don’t fit right. ok solved that put the bracket on first then nudged it over then the cover fits so looks like it will work I am now going to wire the official BL touch kit. won’t fit it yet as need to remove the x gantry to fit the z linear kit.

lets strip everything off to fit the braket

the one thing I will say about fitting all these parts is there are no instructions just wish that aliexpress manufactures would think about this as would make life easier for us end users.

Kit available here

only reffrence i have for assembling the rails.

time to strip down the z-axis and liberate it from the machine then to install the left and right z rail all fitted and now to rebuild x-axis with new brackets. the machine is starting to come together just need to fit the extruder.

had to rotate x motor to get it to fit with the bracket supplied. next up I fitted some side struts for rigidity lets see if they help. can find the struts kit here

I just need to fit the BL touch and then do some cable management.

ok now to flash the firmware with Creality ISPprog.exe all done time test. lets do a auto home. argh, mods not allowing me to hit the end stop time for some mods some m3 nuts will act as spacers for the motor mount now works, as with any project some times just need to think out of the box.

Right auto home x and y hitting wait a moment I have no z oh I see flashed it with standard merlin. Reflashed and all works had some binding issues with z that I have fixed by adjusting the threaded rod screws and my trust spirit level.

Now to offset z so we can start to test what the mods have done for this machine and will I be doing further mods let see quite nervous about the first print.

final bits to install z rod ends are now installed.

time to find a sheet of paper and see if my machine calibrates ok fingers crossed.

away we go auto home done over to Prepare menu then » Move Axis » Move Z now to lower the z till it grabs the paper and then make note of the amount and then go over to

In my case it’s -01.50 go up to the main menu then go Control » Motion » Z Offset enters —01.50 time to store the offset.

go back to the Control menu, then select Store Settings. The job is done now to test print

Failure of the bog-standard Creality firmware 1.60 has issues I think the printer is heating auto homing then going through the bed levelling part then it starts to extrude and rocks backwards and forward on the front of the bed. hmmm

F@@K it 8bit Creality board can go do one time to spend some money as I said going to throw upgrades at the printer till it works right.

Have ordered bigtreetech skr mini e3 v2 with TFT screen so will be compiling my own version of marlin for my 32bit board.

I think I will also swap to linear rails kit for Y-axis I might just sell on the custom bed as the kit comes with all the parts including the bed.

so I am going to end this here till I have the new mainboard and can make some progress.

more to follow.

19/09/202119/09/2021

Adding keyboard draw to my workbench

The Problem

Ok, what’s so hard about adding a keyboard drawn to a desk well if my desk was solid wood would not be a be an issue but seeing as I cannot afford a nice metal or wooden workbench I have gone down the 1200 x 600 racking route. and have had to balance my keyboard on shelves under the desk no so easy when the bench is full.

The Idea

had been bugging me this for some time I was going to make my own draw using some wood and draw runners. but then was thinking back to my days in IT when we had a massive server cabinet with keyboard draws. so straight on to amazon. found 3 or 4 possibles but none had the right mounts or size for the keyboard I am using.

I then found laptop draws and that was the answer to my issues. prime delivery next day now to make this fit. been running ideas in my head since yesterday on how to fit it as fits the 50mm gap I have created.

The plan

I am going to cut down 1.8 meters 50×47 mm wood into 600mm lengths 3 of them.

I will then measure and drill holes fro draw mounting points through the wood I will countersink them so I can add bolts flat to lengths will then blot them to the 2 lengths.

the 3rd length I will use to strengthen up the end of the bench will be making a quick release for the table saw, pillar drill and sander. more on that in another project.

I will now measure up the tabletop and drill 3 holes and countersink them into the tabletop will then screw down the tabletop after that is complete I plan to use carpet tape to hold down the cutting mat. well that’s the plan wish me luck

The build

Monday Night:

Hand saw out 3 legs cut. time to test fit them. ok, Need to take 5 mm off each length as slightly too long going to notch out the top and bottom so it fits in the frame. Have one done works just need to set up the piller drill as want my holes to be true then will test fit

I want them sitting nicely in the frame as screws from above will clamp them down onto the tabletop. hold on now waiting on bolts as I could not find any locally so amazon delivery tomorrow. will notch other 2 lenghts tommorow.

Tuesday Night:

Time to replicate the frist length 2 more times and fit every one more time before i put the top back on.

Now to measure drill and countersink. fits like a glove now drill the tabletop. on a roll now to stick cutting mat down as this project done.

Share this:

Like this:

So what this part covers:

All in one Cr-10 Remixed for Dual Y-Axis linear rails kit

Time to build it.

Yay parts from china

UPS big tree tech

Filament runout sensor big tree tech

Time to modifiy my racking

TFT Screen firmware configuration

Dragon Hotend and issue correction

BISQU Flexplate

Share this:

Like this:

Y-Axis Linear rail upgrade

Share this:

Like this:

Share this:

Like this:

Share this:

Like this:

High voltage side.

Low voltatge side.

How my plans have changed

Share this:

Like this:

Fixing the reversed Y-axis:

Installing the updated motor mount and bed upgrade:

Time to invstigate whilst i wait for new bracket:

Fit proper X-axis linear rail bracket.

Reinstall hotend with direct drive & Install new hotend part cooler mod.

Time to print a camera mount:

Calibrate and do some calibration prints without issue,

Share this:

Like this:

Compiling merlin for the first time.

So out with the old in with the new:

Time to switch it all on

Time to print some Upgrades whilst i am waiting on parts

Share this:

Like this:

Share this:

Like this:

Share this:

Like this: