3FPD-Replicator 2X - Extruder Upgrade - REV3

This is an extruder upgrade designed specifically for the Replicator 2X similar to whpthomas, and others, but with improvements.

-base is fully printable without s(REV3=DESIGN TWEAKS)

-arm is printable with only external s (bearing slot)

-arm integrates feed tube mount as well(REV3=DESIGN TWEAKS)

-tension spring geometry improved (REV3=MORE TENSION)

-use 5/32" and 1/4" bits for tight clearance bearing/arm pivot holes

-uses Makerbot hardware kit for Rep2 + 1 extruder screw ($8 ea from Makerbot.com)

-can be pre-assembled for quick swap (under 2 minutes each)

-L and R extruder parts included, and labelled (common pin)

-Acquire the Rep2 extruder upgrade kit hardware only. ($8 ea shoudler bolt, small FH screw, bearing, spring) from Makerbot

-I printed it at 0.27mm layer with no on base, and external s for the arm just because of the bearing channel.

-you will need to chase the bore for the bearing shoulder bolt with a 5/32" drill bit just to make sure it is a tight fit.

-you may need to chase the 1/4" pivot hole in the arm to make sure it is a tight fit as well.

-you will need to lightly file the pin flats, and round edges to make it fit tight into the base key slot

-the base key slot has a relief at the bottom to make sure the pin seats flush and square with no radius in the corners

Pre-Assembly:

-included parts are LH-Arm, LH-Base, RH-Arm, RH-Base, and a common pin (print 2 of them, and one each of the others)

-put the small flathead screw into the deep corner countersunk hole in the base part.

-put the pin into the arm part so it is flush on the outside face

-put the bearing into the arm slot and secure with the shoulder bolt

-shoulder bolt head should be flush to the outside face, and the threads should stick out the back

-bearing should spin freely

-put arm onto base rotating the pin so the shoulder bolt threaded end rests in the curved slot in the base face.

- now that the movement is limited in the arm via the threaded end in the slot you can add the spring

-place the spring on the bottom perch and compress it into the arm perch.

pre-assembly complete.

-follow makerbot instructions on how to remove the existing extruder.

-place the newly pre-assembled extruder upgrade onto the stepper. You may have to compress the arm slightly to move the bearing out of the way of the drive gear.

-new extruder should seat flush to the stepper face.

-use one of the long flathead screws from the removed Makerbot extruder through the corner pin to secure the new 2X extruder the stepper.

-tighten until snug, but arm moves freely with very slight resistance.

-press the arm down until you can insert the hex-key though the arm hole to tighten the small flathead screw in the other corner.

-repeat entire procedure for the extruder upgrade for the other side.

Please let know if you have any suggestions on improvements.