Bowden mount, optical autolevel and direct drive extruder for the Wilson TS or similar I3 based printer

thingiverse

Here are my modified Wilson TS parts. I've made several changes to improve its performance. Firstly, I replaced the Wade-type direct extruder with a Bowden extruder to minimize weight on the moving parts. The mount I used was inspired by http://www.thingiverse.com/thing:381061, and I rebuilt it from scratch in SolidWorks to optimize airflow and ensure it fits an E3D V5 Chinese clone hotend (a great hotend when handled correctly). The extruder itself was based on http://www.thingiverse.com/thing:245677, but I redesigned the base for easier mounting on the side of the Wilson. My design incorporates a MK8 drive gear. Additionally, I added auto-bed leveling inspired by http://www.thingiverse.com/thing:263180 and rebuilt it from scratch to utilize a printed part and an M3 machine screw as a rod. This version is lighter and easier to produce. The system employs an optical switch for precise readings, and the spring is optional but useful in achieving gentle rod movement (gravity takes care of it otherwise). To drive this auto-leveling system, I chose a SG90 9G micro servo – affordable, simple, and highly effective. If you have questions about these modifications, please feel free to ask in the comments section. I'll be happy to assist. For configuring the auto-leveling feature within Marlin firmware, I recommend consulting Zennmaster's instructional video at http://zennmaster.com/random-things/auto-bed-leveling-for-the-makerfarm-prusa-i3-part-2-setting-up-marlin. A video demonstrating the system in action is available here: https://www.youtube.com/watch?v=iIzJnyOk_vg. Best of luck with your Wilson mod, and thank you for stopping by! **Instructions for Assembly** All parts are suitable for printing without support. Printing settings: * 0.3 layer height * 3 perimeters * 15% infill (except extruder parts, where 40% infill, 4 perimeters, and a lower layer height were used due to the necessity of strength) You will need the following components for assembly: **Bowden Mount** - Four M3x30 machine screws - Four M3 nuts - Fan mounting screws (usually included with fan assemblies)