E3D Fan duct and Mendel 90 X carriage for LM10UU

thingiverse

This modification utilizes an E3D hotend on a Mendel 90 "Sturdy" variant featuring LM10UU bearings and T5 belts, with limited space for the standard fan duct. A solution was found by attaching the fan to the X carriage like this example: http://www.thingiverse.com/thing:157992. A normal thickness 40mm fan is suitable for use. To accommodate the E3D hotend, the extruder required a shallower indent, leading to a modified Wades extruder. The hot_ends.scad function's jhead_groove_offset() was changed to 3.8. The included fan duct comes with pre-included thin lines of support material, but Cura's support material removal proved challenging. An alternative fan duct can be used from this source: http://www.thingiverse.com/thing:91931, though it remains untested. To build this modification, use the following parts and instructions: 1. Printed fan duct 2. Printed X carriage 3. Modified Wades extruder with a shorter indent 4. Assembled E3D hotend 5. Standard Mendel 90 parts After printing, remove support material from the inside of the fan duct. Attach the fan duct to the fan using M3 screws and M3 hex nuts. Be cautious when disassembling, as captive nuts can be difficult to align. If using hex head bolts on the Wades extruder, use shorter ones and install them before putting the motor in place. Attach the E3D hotend to the modified Wades extruder with M3 screws and washers, following the Mendel 90 manual's instructions. Set up the X carriage by attaching the Wades extruder while ensuring that the fan duct isn't obstructed. Install zip ties in the X carriage for future use but don't close the loops yet. Place the "block" end of the zip tie towards the middle of the X carriage. Attach the modified Wades extruder to the X carriage, taking care not to use wing nuts that may obstruct the fan duct. Attach the fan (without the duct) to the X carriage using M3 bolts and M3 hex nuts. Then, attach the fan duct with M3 screws from a previous step. Install the X carriage on bearings and rails, securing zip ties in place. Finally, run additional wires for your always-on fan.