Fan duct and Mini Differential IR sensor mount for E3Dv6 hot end with commonly used mounting plate

thingiverse

I designed an alternative fan duct for my delta but decided to modify it instead so that it could fit my existing Prusa i3 and new CoreXY. To achieve this, I changed the mounting plate from the "Kossel effector" to standard 50mm spaced M4 holes commonly used in Greg's Wade Extruders. I also increased the diameter of the fan hole slightly to reduce air resistance. The primary reason for using this mount was that I wanted to utilize dc42's IR sensor and eliminate the original E3Dv6 cooling fan mount, which I deemed the only weak aspect of my design. The IR sensor mounts were always getting loose and rattling around. I have included files for two different duct types: one designed for v1.0 IR sensor and another for the smaller v1.1 version. To install, I mount the PCB on the front instead of the back, allowing it to be further away from the hot-end. Additionally, a thin sheet of stainless steel wrapped in kapton tape is mounted on the back as an extra heat deflector. Files are also available for a spacer plate, but this is only required if you plan to install the fan mount on a G&C CoreXY printer (www.thingiverse.com/thing:1003119). I apologize for the poor pictures of this piece due to difficulties in capturing a clear shot when mounted on a printer surrounded by many parts. Many thanks go out to the original designers, as my modifications are quite minor compared to their exceptional work! **Print Settings** Printer: Prusa i3 Rafts: Doesn't Matter Supports: Yes Resolution: 0.2 or 0.3 Infill: 30% - 40% Notes: I printed mine using ABS, with the mount plate downwards (using a brim). Removing the support is relatively easy as it only appeared in the fan chamber during my prints. The E3Dv6 is a very tight fit on the mounting plate – you might need to scrape some plastic before sliding it fully into the slot. A snug fit is crucial to avoid any wobble. Mounting a 40mm fan using M3 screws (don't drill out the holes beforehand) should be possible. Note that you still need something above this part to locate the top of the E3Dv6, just like with other mounting plates – usually the bottom of the extruder or part of the X carriage bracket.