JML Bowden carriage mod for the Wanhao i3 Duplicator

thingiverse

This is a customized carriage for the Wanhao i3, designed and printed over an extended period of time to achieve maximum lightness and minimal weight. The primary reason behind designing this carriage lies in its ability to weigh significantly less than the extruder alone (165 grams as opposed to 220 grams), thereby eliminating potential issues caused by inertia from excessive weight swinging back and forth. To assemble the carriage, you will require the following components: 1x M5 x 40mm with nut 4x M4 x 20mm with nuts 1x M4 x 15mm without a nut 1x blower fan The original belt on the carriage was also replaced due to having spare parts. To accommodate varied preferences, I have provided an option to adjust the height of the hotend by ±2mm, enabling users to choose between tighter springs on their bed or a glass bed at a desired height. Regarding the fan shroud, it has been designed with a snug fit around the hotend, ensuring minimal heat radiates and does not cause problems with the fan shroud. However, for users who may encounter issues with this design, I am prepared to create an alternative version that allows for a larger gap between the fan shroud and the hotend. To assemble the carriage, follow these steps: First, attach an M4 nut to the rear of the carriage before installing the fan shroud. Secure the fan shroud using an M4 x 15mm screw. Then, connect the blower fan via M4 x 20mm screws. Make sure all components are securely attached to the carriage bearings. Next, guide the belt through the grooves on the left side of the carriage and the small opening on the right. Attach an M5 nut to the Tension clip and position it above the belt, ensuring the clip is tightly secured to the right-hand side of the carriage. The belt should be hand-tightened before adding the M5 screw, which should be tightened firmly but not excessively. Subsequently, attach the front carriage by securely fastening it to the rear carriage using an M5 x 20mm screw. Then, add the ±2mm bracket, orienting it so that the Bowden hotend is positioned at its highest point. Secure this bracket with two M4 x 20mm screws. Finally, locate the stopper on the top left side and attach it to the existing screws. If you are using a glass bed, remove it first, then set home and assess the gap. Once satisfied with the height, reinstall the glass bed and adjust the brackets as necessary to achieve your desired setup.