Prusa I3 Rework Chimera mount with BLTouch platform

thingiverse

Human: Successfully completed model creation on 2015-12-12, with plans for print and fit testing tomorrow of Chimera and BLTouch sensor. This model is designed using precise measurements taken from invent0r's STL file in 123D Design software, combining those measurements with detailed design specs provided by Charles Lee and the BLTouch team. Edit(2015-12-14) I printed it out yesterday and parts fit are surprisingly good. Minor adjustments of holes were necessary, but hex openings fit perfectly for the 4mm nuts. The BLTouch pin lines up directly with both extrusion nozzles, and when retracted, is situated between 2.5 and 3mm above the nozzles. It remains to be seen if this is the ideal position, however it appears that the necessary adjustments could be made using washers. Ideally a print cooling fan would be mounted to this setup. Edit(2015-12-14) I uploaded a revised version of the model, removing text labels but incorporating mounting points for print cooling fans. In order to streamline the installation process, I plan on leveraging the existing fan ducts and mounting arms from Thingy #540716. Printing will commence tomorrow with subsequent inspection of fit and function. Edit(2015-12-15) I successfully printed out a new version featuring fan mounts, which is promising in terms of its overall design. With the revised model, the process can now be turned towards what promises to be a more challenging endeavor - the dreaded teardown and conversion from stock to Chimera hardware. My fingers are crossed that the result will be worth the trouble. Edit(2015-12-21) The tear-down was successfully completed over the weekend and all parts fit together perfectly. However, one issue did arise: standard Pi3 Rework x-axis endpoint switch location is not being struck as intended. As a makeshift solution, I chose to glue a small piece of scrap print into position. This afternoon, I made additions to the design for the x-axis endpoint trigger "finger" and reprinted with the prior mount setup in use. Plans are underway to replace this part with the new one later tonight if circumstances permit. In relation to the BLTouch sensor and mounting bracket, everything lines up perfectly, boasting no y-axis offset, a modest 19mm x-axis offset, and an equally slight -.48mm z-axis offset. Following a few test iterations to fine-tune everything correctly, it is now operating smoothly. The worry of getting the bed manually levelled every time I use it has been largely alleviated although I do plan on regularly inspecting it in this regard and providing it with some minor manual adjustments if necessary. Not least among my reasons for wanting an even more accurately calibrated printer was that my new Chimera will necessitate a fairly levelled printbed, meaning both nozzles need to be set at the same height relative to the bed. In due course I will endeavour to obtain high-quality images of this part and perhaps film its use. (https://www.youtube.com/watch?v=KbuQ6rgdl1c&feature=youtu.be)