Kossel construction notes

Preamble

Following on from Kossel 3D Printer, these are some points that I have noted, whilst constructing a Kossel XL using the Sintron kit and a Kossel mini using aluminium vertices…

Assembly gotchas

Parts

Bolts for frame

Using the aluminium vertices:

  • M5 x 10 mm bolts are required for the Aluminium vertices, not 8 mm as suggested by the RepRap Wiki:Kossel.
  • The aluminium vertices do not have gaps to enable additional nuts to be slipped into the aluminium extrusion, after the top and bottom deltas have been constructed

Using the Sintron kit:

  • M3 x 8 mm bolts are used for the frame.
  • The vertices have gaps for additional nuts to be slipped in horizontally. But not vertically.

Using the Kossel kit from M.Rut3D:

  • M5 x 10 mm need to be used, or 12 mm – 8 mm are too short.
  • The vertices have gaps for additional nuts to be slipped in horizontally. But not vertically.
  • The vertices have slots, for screwdrivers, to ease the steppers motors to be screwed on

Aluminium

When fitting the motor nuts, remove the frame bolts, or fit motors before the frame. The M3 x 6 mm bolts used to secure the steppers are hard to tighten, due to poor access.

It is easier to insert nuts into the extrusion and then, after positioning the nuts correctly, screw the vertices to the extrusion, rather than sliding partially screwed on nuts into the extrusion (as done for the Sintron kit).

The top vertices bearings, because the M3 bolts do not screw in to the vertices, as there are no threads. Use M3 x 25 mm bolts, with:

  • M3 washer
  • F623zz
  • F623zz
  • M3 washer
  • M3 washer (optional – it is rather tight)
  • M3 nut

Kossel/m.rut3d

Extruder

Insert three M3 nuts into the outer face of one of the verticals for the [printed] extruder stepper motor holder.

Build Plate

Insert one nut into two of the upper bottom horizontals and two into one, for the build plate holder. Check whether the holes in your [printed] build plate holders are M3, M4 or M5 – the m.rut3d printed build plate holders require M3.

Endstop

Insert one M3 nut for the printed endstop switch holders into each vertical length of aluminium extrusion, on the inside facing the print bed. Be sure to insert them prior to assembly of the vertical extrusions.

Sintron printed parts

Extruder

Extruder mount – two M3 nuts on the top face of one of the upper horizontals

Reel holder

Insert one nut into two of the top horizontals and two into one, for the reel holder. Check whether the holes in your [printed] reel holders are M3, M4 or M5.

Build Plate

Whilst the Sintron kit has no printed parts to secure the build plate, nuts are required for the bare bolts (M3, M4 or M5 – up to you) used instead. Insert one M3 or M5 nut into two of the upper bottom horizontals and two into one, to secure the build plate.

Endstop

See More endstop madness, in the blog Kossel 3D Printer – Fasteners, use two M3 T-nuts/flanged nuts for the end stops and printed endstop switch holders into each vertical length of aluminium extrusion, on the inside facing the print bed. Be sure to insert them prior to assembly of the vertical extrusions. The PCB mounted end stops are M3 holes. Note that the mechanical switches alone, have M2.5 holes.

 

 

 

 

 

 

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