Beefier Extruder Idler Lever Arm

thingiverse

Emmett's extruder was one of my first upgrades for my Replicator 1, added in summer '12. It improved performance immediately. Since then, it has been daily use and remains reliable. Recently, though, I experienced occasional ghost printing issues. Puzzling! Upon closer inspection, I discovered a tiny crack at the filament feed hole in Emmett's lever. To remedy this, I slightly redesigned that area to make it more robust. Additionally, I increased the lip size to catch the spring better on the high side and expanded the recess for the spring to match my standard Home Depot spring. Despite the extruder's weakened state, I managed to print a new arm with some manual assistance. It was an awkward process but resulted in a successful repair within 90 minutes of noticing the crack. The future is here, and our machines can even fix themselves - what a day!