With all the materials gathered it is time to assemble Plan B. This step will take around a day, depending on the amount of problems you will encounter. For assembly, you will need an assortment of wrenches, screwdrivers and allen keys. An electric screwdriver will cut down the assembly time by a ton. There currently isn’t a step by step picture assembly guide. All there is is a bunch of technical drawings and some pictures of the complete assemblies. If after this guide there are any questions left the can be asked in the contact me section. The questions will be answered as soon as possible and information might be added to the page if it seems to be missing. Low res versions of the drawings are displayed on this page, higher resolution images can be downloaded below.
Onward to the guide.
It’s best to start assembly with the pistons. The frame needs to adjusted to the sides and the axes of the pistons. Assemble the sub assemblies and mount these to the piston frames. At this point getting it exactly right doesn’t matter yet.
The spreader is easiest to mount to the frame while the frame is under construction, so it is next. It is best to assemble the bearing holders, but not yet join them with the 2 rods and the aluminum tube. This will be in the way of mounting it to the frame. Assemble these parts after the frame is assembled. Assembly of the spreader is pretty straight forward.
Now assemble the frame. First assemble the sheetmetal portion of the frame. All connections are made using T-slots. M3 nuts fit in the slots and a screw and a washer thread in to this nut. When the sheetmetal frame is assembled test fit the pistons. The frame needs to be as square as possible and all pistons need to have a gap smaller than 1mm to all sides on all heights. A consistent gap is more important here than a small gap, because a consistent gap can be filled with tape.
Fit the bearings for the pistons underneath the frame. Adjust these bearings until the pistons run smoothly. Also the bearings that run on the walls can be adjusted now to run on the sides of the hopper. At this point the endstops need to be mounted. Plan B functions perfectly well without these endstops, so this part can be skipped. They are just added safety.
Then assemble the plastic parts of the spreader axis. While assembling, mount the pre-assembled bearing holder of the spreader. When assembly is done you can joint both holders with the tube and threaded rods.
Assembling the carriage is fairly simple. The carrier for the cartridge is mounted with cable ties to the body of the carriage. The bearings are also mounted with cable ties. Don’t tighten the bearing ties too much, the bearings needs some freedom to adjust themselves to the rails.
Assemble the Y-axis. Assemble both bearing holders. Then fit the smooth rods in one holder and slide the carriage on (look at pictures to figure out the orientation). Then slide the other bearing holder on and adjust the carriage bearings (by simply pushing them) until the carriage runs smoothly across the Y-axis.
When all sub-assemblies are done, put everything together. Put the entire gantry on to of the printer. The pistons go in the frame after the printer is wired, there is no way to move the lead screws without power.
Make sure everything runs smooth. Move all axes by hand to check if they have any resistance. If there is too much resistance, Try moving the bearings by hand or loosen the screws a bit to give the bearing more space. When everything runs smoothly, the belts can be attached. The printer will need belts on the X, Y and S axes. These belts have been marked yellow in the schematic. The S and Y axis need a belt on either side, the X-axis runs through the entire printer. The belts are T2.5, 5mm wide and the pulleys have 16 teeth.