Assembling the front threaded rods

I ran into an issue while assembling the front threaded rods...

Front threaded rod assembly - ran into issue with fender washer

I ordered the wrong size of fender washer - I should have ordered M3x30, but i ordered M3x25...

So the outer diameter of fender washer and the 608 bearing is very close. The timing belt will not seat properly on the 608 bearing. I need to order fender washer - M3x30. Until the part arrives, i am stuck here.

Done for the day!!!!

Assembling Frame vertex triangles

Today, i started assembling the frame vertex triangles..

I followed the instructions on the site: http://garyhodgson.com/reprap/prusa-mendel-visual-instructions/.
I also downloaded the High resolution PDF file.

Before i started assembling, i made two jigs - one 290 mm in length and the other 234 mm in legnth.

This is how made the jigs

1. Took a wooden scale ( bought earlier from HomeDepot - I think it is for $1 dollar) and marked and cut exactly 290 mm from one end and 234 mm from the other end..(Because if there is any imperfection in cutting, it will not impact the other Jig)

Trust me, make sure you made the jigs!!!!

Showing the threaded show + Jig of 290mm

Make sure the jig of 290mm snugly fit between the vertex.

Measure all the three sides and adjust the nuts if necessary. I thought it will take some time precisely measure the distance, but it a breeze with the Jig...

Create another frame as similar to the above. Once i am done, here is the image of two frame vertex triangles...

Two - frame vertex triangles

Resolved the issue with 8 mm smooth rod fitting into the Oilite bushings

I ran into an issue 8 mm smooth rod fitting into the Oilite bushing.

1. The inner diameter of Oilite bushing is 8mm and the smooth rod (metric) is exactly 8mm. So the smooth rod doesn't go into the Oilite bushing. 
2. I bought 8.1 mm drill bit and i drill through the Oilite bushing and now smooth rod is moving inside the bushing. Issue resolved...

8 mm smooth is smoothly moving inside the bushing

Another view of 8 mm smooth rod + bushing

Sept, 04 2011

All the blog posts on Sept, 03 2011 were happened earlier. From now onwards, i will blog on the same day as the events unfold....

Arcol Hot End

RepRapLog phase - suggested 'Arcol' hot end is an over engineered beast. So i decided to buy the 'Arcol' hot end.

The main reason to go with 'Arcol' hot end is, in any RepRap printer...hot end is the key component.

I want the key component as reliable as possible. I want to go by 'reliable' route rather than saving a few dollars...

This is what i ordered -

1.  Arcol hot end v.3 preassembled with 0.5 mm nozzle
2. 0.3mm nozzle
3. Wade's extruder threaded bolt. (The reason for ordering this one, this one is precisely built. Some one from PA, USA gave a good comment on this one.This is the part that will feed PLA to Hot End.)

Total price: $159.90

I have not received the parts yet...Even though they were shipped  on 8.27.2011 from UK..

Ordered the RP parts(metric) from eBay

I found RP parts(Metric) on eBay for $84.99 with free shipping. I contacted the seller and ask few questions about the color, requested to ream the parts and whether it suits the Arcol hot end.

Seller obliged my request to ream the parts and confirmed it suits the arcol hot end.

There are couple of differences with the parts, i ordered.

1. Accessible wade extruder:  The advantage is, it is easy to change the filament using 'Accessible wade extruder' when compared to 'wade's extruder'
2. Oilite bushings: The advantage is Long life and smooth operation when compared PLA bushings.

I got the parts and a surprise awaits me...The smooth rods i bought (metric) doesn't go through the Oilite bushings. I contacted the seller and he suggested to buy Imperial smooth rod from HomeDepot...

I have to decide what i have to do? While ordering the hardware parts, i ordered a 8.1mm drill bit..

Here is my two options..

1. buy imperial smooth rods
2. Drill through the Oilite bushings with 8.1 mm drill bit..

Cutting the smooth and threaded rods...

Bought hacksaw blades from HomeDepot to cut the rods as below...
Need to add the cost of the blades

3x1m Long 8mm Smooth Stainless Steel Rod

 Rod 1: 420mm, 420mm
 Rod 2: 406mm, 406mm
 Rod 3: 350mm, 350mm

6x1m Long 8mm Threaded Rods (or 5x1m pieces + 1x50cm piece)

 Rod 1: 370mm, 370mm, 210mm
 Rod 2: 370mm, 370mm, 210mm
 Rod 3: 370mm, 294mm, 294mm
 Rod 4: 370mm, 294mm, 294mm
 Rod 5: 440mm, 440mm
 Rod 6: 440mm

I am able to cut the smooth rods on one evening within an hour or so.
and cut the threaded rods on the following weekend with the help of wife.

Bought the blades from HomeDepot

Smooth and threaded rods before cutting

Smooth and Threaded rods cut to size

  
Suggestion: Cutting the rods is tedious.Try to order rods pre-cut.

Rods are ready for assembly..but i have not ordered the RP parts yet.