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2x:2.x_frame_assembly

2.x Frame Assembly (Under construction ... reference only)

Overview

Building the frame is one of more enjoyable parts of the project. It is like working with a scaled up erector set. There is one catch…the frame is assembled using t nuts in the slots. The lower cost t nuts must be slid into the slots from the ends. Since many extrusions get covered on each end by other extrusions, you must plan ahead with the nuts. Many nuts are used to mount brackets and skins much later in the build so it is difficult to figure it out as you go.

We have tried very hard to document all the locations of the nuts, but you will forget some. There are two solution to this. The first is to disassemble one end and slide in the nut. The second solution is to use post assembly t nuts. These nuts drop into the slots from the side. The only problem is they cost quite a bit more. At some point you will be so far in your build that you not want to disassemble. Trust me, at some point you would be happy to drop $5 bills into the slots rather than disassemble. I would suggest buying about 20-30 extra drop in nuts. Some nuts with the spring loaded ball are already on the BOM. These are used when you need them to hold their position on vertical rails.

Tips

  • Usually it is easier to install the screw and t nut onto the bracket first then slide the whole assembly into the slot.
  • Screw the brackets firmly onto one extrusion before attaching it to the next extrusion. It can always be readjusted later.
  • Use a flat surface as a reference when building to make sure the frame is not twisted.
  • The first few pieces are the hardest to build and keep square. Once the frame starts getting some structure to it, it gets easier.
  • Once the frame is done check every corner for proper location and squareness. Readjust as required.

Brackets

There are three different types of brackets used. Be sure to use them in the correct locations. Most places use the cast corner brackets, but those interfere with the Makerslide V feature.

HBLFSN5 HBLTS5 HBLSS5
Default Ends of Y Z Motor crossbar

Assembly

Use the image below and the instructions in the table to build the frame. The drawing also shows the part numbers and the spacing of the parts that are not on the ends of other extrusions.

NOTE: This table also contains the number of EXTRA t-nuts that should be installed during assembly. It does NOT account for the t-nuts that are necessary to connect that piece other pieces of frame. Therefore, you should be looking carefully at the diagram above and include any t-nuts you will need to connect this frame piece and any frame pieces in a later step.

(Right, rear, etc are stated as if looking at the piece, after installation, from the front.)

The numbers represent the suggested order of assembly.

I have no doubts that some of these numbers are wrong. The table will continue to be updated as the new information is available.

Assembly Table

Here is a link to an alternate t-nut table - link

Step Description Part Top Right or Rear Bottom Left or Front
1 Assemble Left End
a Bottom 2020-560 2 2 3 1
b Top 2020-560 3 2 0 1
c Rear 2020-310 0 0 0 1
d Front 2020-310 0 1 0 0
2 Assemble Right End
a Bottom 2020-560 2 1 2 2
b Top 2020-560 2 0 0 2
c Rear 2020-310 0 0 0 0
d Front 2020-310 0 0 0 0
3 Front and Back Horizontal Bottoms (ties left end to right end)
a Front 2020-960 0 3 3 1
b Rear 2020-960 4 1 3 3
4 Bottom Horiz(ties front to back) 2020-560 0 0 0 0
5 Bottom Horiz (ties left to other bottom hor. just installed) 2020-730 0 0 0 2
6 Mid-line Horizontals
a Rear 2040-960 4 0 0 0
b Front 2040-960 4 0 0 0
7 Bottom Skin and Feet SEE STEPS BELOW
8 Mid Vertical (back of work area) 2020-160 0 0 0 0
9 Front Vertical (right side of work area) 2020-090 0 0 0 0
10 Rear Top Horizontal 2020-960 2 3 0 1
11 Top Horizontal (front to back - right side of work area) 2020-560 2 0 0 0
12 Front Top Horizontal (above control panel) 2020-230 2 0 0 0
13 Top Horizontal (left to right at rear of work area) 2020-730 4 0 0 0
14 Top Horizontal (left to right at front of work area below lid line) 2020-730 0 0 0 2

Install Feet and bottom Skin

  1. Roll the frame upside down.
  2. Tap the bottom of the (4) corner extrusions with a #10-24 tap. The size of the existing hole is fine as a pilot hole.
  3. Bolt on the bottom skin. Be sure it is oriented correctly. Gloss side faces up. Look for the two closely spaced holes for the end of the cable carrier to be on the right side of the central area. Use the skin as a gauge to pre-position all the t-nuts. Install each screw just enough to grab a few threads. This will allow it to slide around a bit to get all screws. If you one gets out of position, a strong magnet can be used to slide it back in position. Once they are all engaged center the skin and fully tighten.
  4. Install the feet. The threads on the feet are probably longer than you want. I cut mine down by about half.
  5. Install Y axis cable carrier. If you are using a Y axis cable carrier, you should install one end to the bottom skin. It is much easy while the bottom is accessible.
  6. Level the frame. Return the frame to normal orientation and adjust the feet until the frame is level.

Frame Assy FAQ

  • What brackets do you use to mount the middle cross member (supports Z motor) - Use Misumi brackets p/n HBLSS5. See the drawing.
2x/2.x_frame_assembly.txt · Last modified: 2013/01/27 22:36 by bdring