Airwolf HD(x) Extruder

thingiverse

I was thoroughly disgusted with the original filament extruder assembly on my Airwolf HDx. The chances of anyone else still using this printer are slim, but I'm taking a chance and sharing this just in case. This new assembly incorporates most of the hardware from the original setup, along with a few additional components (as shown in the images). You'll need: (1) A 1/4-20x4" bolt (2) A 1/4-20 furniture nut (this is the barrel piece that serves as the pivot point for the bolt; at Ace Hardware, it's located in the "Furniture Hardware" bin) (3) Two 1/4" washers (4) A 1/4-20 wing nut (5) A spring (it fits over the 1/4" bolt and is tricky to compress with your fingers; experiment with different types until you find one that works) (6) Three 3mm diameter x 10mm long, tapered head screws; about 1-2mm will need to be trimmed off so they don't pierce the bowden tube too deeply The following original components are not used: (1) Bowden tube connector (2) Springs (the ones that came with the original assembly) (3) An 8mm flat washer When printing the base, orient it flat side down and you won't need any supports. The other two parts will require some support to print properly. For the tensioner, I suggest printing the "cup" section sideways or horizontally; this requires more support, but makes the hinge point stronger. A picture showing the correct order of assembly for the hobbed bolt is included below. From there, it's pretty straightforward based on the other photos. Keep in mind that the bearing and small axle inside the tensioner don't need any washers. I recommend applying thread lock to the 1/4" bolt where it threads into the furniture piece; you'll see why when you use it.