Mikes Hot End v2.5

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NozzleMachining Steps 1. Position one end of the bar for machining. 2. Create a center divot, ensuring alignment is critical. 3. Drill an orifice with utmost care, going in approximately 2mm using small increments. 4. Employ compound cross feed to taper the tip; a 45-degree angle is recommended for a smooth finish. Verify that no divot remains and the orifice is clear. 5. Part off the tip, leaving some extra length. 6. Face the new end and create another center divot. 7. Measure the nozzle's length and set the tailstock to zero with the sharp tip flush against the nozzle's end. 8. Drill in up to 1.5mm less than the nozzle's length. 9. Utilize a flat end mill to create an internal edge, leaving the center taper intact. 10. File flats at the nozzle's end and ensure the nozzle remains clear. Barrel This new design features fewer steps but is easier to drill through the 4mm hole due to its shorter length, which can be challenging on drill bits. Machining Steps 1. Perform a rough cut from stock material. 2. Face one end and create a divot with a center; alignment is crucial. 3. Drill all the way through using the 4mm drill bit, taking your time and applying plenty of cutting fluid. If the drill bit wobbles at the start, it's off-center; try again. 4. Mark the side that began drilling from and flip the part over to face the other end. 5. Drill in 5-10mm using the 4.2mm drill bit. 6. Tap M5-0.8 with caution, being mindful of the tap. 7. Mount the marked end 5mm into the chuck, ensuring it's straight by threading an M5 threaded rod into the exposed end and clamping in the tailstock. Once material is clamped, remove the 5mm threaded rod and tailstock. 8. Turn down the threaded rod until it reaches 5/16", leaving only threads in the chuck. 9. Finally, cut the thermal break gap (though not essential) with a cut-off tool; be cautious not to go too far, aiming for the chuck. Liner 1. Cut the liner tubing slightly longer than needed. 2. Assemble the Nozzle and Barrel together with the liner inside. 3. Screw in the push-fit connector into the barrel. 4. This should cause the nozzle and barrel to separate; cut the liner by a little less than the amount showing between the nozzle and barrel. 5. When reassembled, the tightened push-fit connector should create a small gap between the nozzle and barrel. 6. Chamfer the ID of the liner opposite the nozzle to facilitate filament feed. Assembly 1. Screw the barrel into the heater block until the thermal break is flush. 2. Lightly screw the nozzle in place, then heat it up to 250C before final tightening. 3. Once cool, screw on the nozzle nut. 4. Insert the liner and tighten the push-fit connector onto it; the connector may need removal when mounting the hot end.