TRI NI TY LABS MENDELMAX 1 .

5 + BUI LD I NS TRUCTI ONS

Page 2

CONTENTS
INTRODUCTION ........................................................................................................................................... 4
Kit Specifics ................................................................................................................................................... 4
Overview......................................................................................................................................................... 5
GETTING TO KNOW YOUR MENDELMAX ...................................................................................... 6
Parts Overview .............................................................................................................................................. 6
PREPPING THE PARTS ............................................................................................................................. 15
Whats Needed? ........................................................................................................................................... 15
Tools: ........................................................................................................................................................ 15
Hardware: ................................................................................................................................................. 15
Steps: ............................................................................................................................................................. 16
LOWER FRAME ASSEMBLY .................................................................................................................... 18
Whats Needed? ........................................................................................................................................... 18
Tools: ........................................................................................................................................................ 18
Hardware: ................................................................................................................................................. 18
Plastics: ..................................................................................................................................................... 18
Steps: ............................................................................................................................................................. 19
Y-AXIS ASSEMBLY ...................................................................................................................................... 29
Whats Needed? ........................................................................................................................................... 29
Tools: ........................................................................................................................................................ 29
Hardware: ................................................................................................................................................. 29
Plastics: ..................................................................................................................................................... 29
Steps: ............................................................................................................................................................. 30
UPPER FRAME ASSEMBLY ...................................................................................................................... 45
Whats Needed? ........................................................................................................................................... 45
Tools: ........................................................................................................................................................ 45
Hardware: ................................................................................................................................................. 45
Plastics: ..................................................................................................................................................... 45
Steps: ............................................................................................................................................................. 46
EXTRUDER ASSEMBLY ............................................................................................................................ 54
Whats Needed? ........................................................................................................................................... 54
Tools: ........................................................................................................................................................ 54
Hardware: ................................................................................................................................................. 54
Page 3

Plastics: ..................................................................................................................................................... 54
Notice: ...................................................................................................................................................... 54
Steps: ............................................................................................................................................................. 55
X-AXIS ASSEMBLY ...................................................................................................................................... 63
Whats Needed? ........................................................................................................................................... 63
Tools: ........................................................................................................................................................ 63
Hardware: ................................................................................................................................................. 63
Plastics: ..................................................................................................................................................... 63
Steps: ............................................................................................................................................................. 64
Z-AXIS ASSEMBLY ...................................................................................................................................... 69
Whats Needed? ........................................................................................................................................... 69
Tools: ........................................................................................................................................................ 69
Hardware: ................................................................................................................................................. 69
Plastics: ..................................................................................................................................................... 69
Steps: ............................................................................................................................................................. 70


Page 4

INTRODUCTION



Kit Specifics
Like every other RepRap kit, the MendelMax consists of customized pieces of hardware that the builder chooses.

The kit described in this log consists of the following components:
Trinity Labs MendelMax 1.5+ Hardware Kit, with upgraded Linear Y-Axis Rail Kit and
Extruder Hardware
Techpaladin plastics, for use with the MM1.5 Hardware Kit: 8 & 10mm Precision Chromed
Rods, Precision Leadscrews with Delrin Nuts, as well as a Jonas Skuehling/Greg/Wades
Extruder
Lulzbot Budaschnozzle 1.1
Arduino Mega 2560, RAMPS 1.4 kit with Pololu 4988 Stepper Drivers
110V Power Supply
110V Silicone Heated Bed
I will be including the X-Carriage instructions that I used to build my kit, the carriage included with
the TrinityLabs kit is a variation of the Supaflat X-Carriage by AlephObjects.

Section

INTRODUCTION
Page 5

Overview
Since not everyone that would like a 3D printer knows what a hobbed bolt is, or a socket head cap
screw, there will be a section outlining all of the parts that were included in the kit.
After the component breakdown, the manual will be split up into sections that will build upon the
previous, but separate the components that are not part of the regular MendelMax kit.
The sections are as follows:
Prepping Parts
Lower Frame
Y-Axis
Upper Frame
X-Axis
Z-Axis
Electronics
Calibration
Each section will list the hardware, plastics and tools needed to build that sections assembly.

PLEASE NOTE: Due to the fact that the community requires this documentation ASAP, I will not
be including the Electronics nor Calibration sections in the initial release. I will follow up with a
second revision that includes these sections.


Page 6

GETTING TO KNOW YOUR
MENDELMAX


Parts Overview
MM Hardware Bag
M3 Nuts x10
M3 Washers x30
M3 SHCS x30
T-Slot Nuts x100
M5x10mm SHCS x120
M5 Thin Nuts x100
M5 Washers x100
M5x12mm BHS x4
M5x12mm SHCS x18
M5x20mm SHCS x8
M5x10mm FHS x4
M8x30mm SHCS x2
M8 Nuts x2
M8 Washers x5
Linear Bushings 8mm x8
Linear Bushings 10mm x4
608ZZ Bearings x8
Z Shaft Couplers M5M6.35 x2
GT2 Pulleys x2

Y-Axis Rail Hardware
M3x10mm SHCS x8
M3 Nyloc Nuts x8
M5x10mm x7
M5x16mm x4
M5 Thin Nuts x4
M5 Washers x11
M6x10mm SHCS x4
Table Corners x4
Rail Belt Clamp x1









Y-Axis Mounting Hardware
Corner x4
T-Slot Nuts x8
M5x10mm x8
M5 Washers x8

Y-Axis Rail Kit
Insulator Plate x1
Rail & Car Assy x1
Borosilicate Glass x1
PTFE Sheets x2

Frame Kit
300mm Extrusions x4
340mm Extrusions x4
420mm Extrusions x7

Heated Bed Kit
Heated Bed x1
SSR x1
M5x65mm SHCS x4
M5 Nuts x4
M4 Nyloc x2
M3 Nyloc x2
M3x12mm FHS x2
Power Jack x1
Fuses x2

Thermistor Kit
Thermistor x1
Connector Wire x1
Grey Wire x1
PTFE 30Gauge Tube x2
1/8 Heat shrink
1/16 Heat Shrink
Section

GETTING TO KNOW YOUR MENDELMAX

Page 7


Linear Kit
Precision Chromed Rods 10mm x2
Precision Chromed Rods 8mm x2
Precision Leadscrews x2
Delrin Nuts x2

Electronics Kit
RAMPS 1.4 x1
Arduino 2560 Mega x1
End Stops x3
LED Strips x2
Budaschnozzle 1.1 x1
Stepper Motors x5
110V Power Supply x1

Extruder Hardware Kit
M8x25mm Stud x1
M8 Nut x2
M8 Washer x4
M4x55mm x4
M4 Nut x4
M4 Washer x15
M3x10mm x4
M3x25mm x2
M3 Washer x10
M3 Set Screw x2
Hobbed Bolt x1
608ZZ Bearing x3



















Plastics Kit
Top Vertex x4
Bottom Vertex - Upper Left x2
Bottom Vertex - Upper Right x2
Bottom Vertex - Lower Right x2
Bottom Vertex - Lower Left x2
70mm Jig x1
Y Motor Mount x1
Y Rod Clasp x4
Y Idler Mount x1
Y Idler Tensioner x1
X End Clamp x1
X End Motor Side x1
X End Idler Side x1
X Carriage for Self Aligning Bronze
Bushings x1
Lower Motor Mount for 10mm Rods
x2
Z- Top Vertex for 10mm Rods x2
Z- Lower Motor Mount Support (A)
x2
Z- Lower Motor Mount Support (B)
x2
Rod Clasp x4
Extruder Idler Holder x1
Extruder Small Gear x1
Extruder Large Gear x1
Groovemount Holder x1

GETTING TO KNOW YOUR MENDELMAX

Page 8















M3 Washer
M3x10mm SHCS
M5 Washer
M5x10mm
SHCS
M3 Nut
M5 Thin Nut
T-Slot Nut
M5x12mm SHCS
M5x12mm BHS
M5x20mm SHCS
M5x10mm FHS
M8x30mm
SHCS
M8 Nut
M8 Washer
608ZZ Bearing
420mm Aluminum
Extrusion
340mm Aluminum Extrusion
300mm Aluminum Extrusion
Figure 1: Frame Components
GETTING TO KNOW YOUR MENDELMAX

Page 9

GT-2 Belt
GT-2 Pulley
Precision Leadscrews
10mm Precision Chromed Rods
8mm Precision Chromed Rods
8mm Bronze Bushing
10mm Bronze Bushing
Delrin ACME Nut
Z-Shaft Coupler M5 to M6.35
Figure 2: Linear Components
GETTING TO KNOW YOUR MENDELMAX

Page 10


M5x10mm SHCS
Corner
T-Slot Nut
M5 Washer
M3-10
SHCS
M3 Nyloc Nuts
M5x16mm SHCS
M5 Thin Nuts
M5 Washers
M6x10mm SHCS
Table Corners
Rail Belt Clamp
M5x10mm SHCS
Y-Axis Car
Y-Axis Rail
Heated Bed Plate
PTFE Sheets
Borosilicate Glass
Insulator Plate
Figure 3 - Y-Axis Components
GETTING TO KNOW YOUR MENDELMAX

Page 11


M8x25mm Stud
M4 Nut
M8 Nut
Hobbed Bolt
M4x55mm
SHCS
M3 Washer
M4 Washer
M8 Washer
608ZZ Bearing
M3x25mm
SHCS
M3x10mm SHCS
M3 Set Screw
Figure 4 - Extruder Hardware
GETTING TO KNOW YOUR MENDELMAX

Page 12

Mechanical Endstop
Arduino Mega2560
RAMPS 1.4
Lulzbot Budaschnozzle 1.1
Solid State Relay (SSR)
Power Jack
M5x65mm SHCS
Fuse
M3x12mm FHS
M3 Nyloc Nut
M4 Nyloc
Nut
M5 Nut
NEMA 17 Stepper Motor
110v Power Supply
Figure 5 - Electronic Components
GETTING TO KNOW YOUR MENDELMAX

Page 13

Figure 8 - X-Axis Plastics
Figure 6 - Frame Plastics
Figure 7 - Y-Axis Plastics
Top Vertex x4 Bottom Vertex -
Upper Left x2
Bottom Vertex -
Lower Left x2
Bottom Vertex -
Lower Right x2
70mm Jig Bottom Vertex -
Upper Right x2
X-End Clamp

X-Carriage - For
Self-Aligning Bronze
Bushings
X-End -
Idler Side
X-End -
Motor Side
Y-Axis Motor Mount

Y-Idler Tensioner Y-Idler Mount
GETTING TO KNOW YOUR MENDELMAX

Page 14

Figure 9 - Z-Axis Plastics
Figure 10 - Extruder Plastics
Lower Motor Mount
For 10mm Rods x2
Top Vertex For
10mm Rods x2
Lower Motor Mount
Support (A) x2
Rod Clasp x4
Lower Motor Mount
Support (B) x2
Idler Holder Large Gear
Groovemount Holder Small Gear

Page 15

PREPPING THE PARTS



Whats Needed?
Tools:
File
Sandpaper
Misc Drill Bits for Reaming
M5 Tap
6mm or Drill Bit
Drill
Hardware:
300mm Extrusion x4
340mm Extrusion x4
420mm Extrusion x2
Plastics
Section

PREPPING THE PARTS
Page 16

Steps:
1. Look over all of the plastic parts to see if there are any pieces of plastic stuck inside holes, or
if the holes themselves are not clean.
2. Use a drill bit that is the size of the hole that you want to clean and push it into the hole to
loosen and remove any plastic bits.
3. Check the outside of the plastic to see if there are any pieces of filament that are loose or
overhanging and remove them with the sandpaper and/or file.
4. While you are inserting nuts into nut traps, if they are not easily slid in, then first check to
make sure you have the correct size nut. Second, use a file or knife to widen the slot a bit, in
order for the nut to fit snug inside.
5. Gather up the 340mm and 300mm extrusions. I found that bundling them together with
tape makes it easier to tap the holes in the ends.
6. Tap all 8 of the extrusions, both ends, and make sure that any debris is blown out of the
holes.
7. Gather two 420mm Extrusions and the 70mm Jig.
8. Line the jig up to the end of one extrusion and using your drill, proceed to drill a hole
through the extrusion.

PREPPING THE PARTS
Page 17

9. Remove the debris and repeat on the other side.

10. Repeat with the other extrusion.

Page 18

LOWER FRAME ASSEMBLY



Whats Needed?
Tools:
4mm Hex Key
Hardware:
M5x10mm Socket Head Cap Screws
M5 Washers
M5 Thin Nuts
T-Slot Nuts
300mm Extrusion x4
420mm Extrusion x4 (Non Drilled)
Plastics:
Bottom Vertex - Lower x4

Section

LOWER FRAME ASSEMBLY

Page 19

Steps:
1. Locate a 300mm Extrusion and place a T-Slot Nut in one of the slots.

2. Get one of the Bottom Vertex - Lower Right pieces and secure into the 300mm Extrusion
with 2 - M5x10mm SHCS and 2 - M5 Washers.

LOWER FRAME ASSEMBLY

Page 20

3. Place 3 - T-Slot Nuts into the other end of the extrusion, in the same slot.

4. Locate one of the Bottom Vertex Lower Left pieces and secure into the other side of the
300mm Extrusion with 2 - M5x10mm SHCS and 2 - M5 Washers.

LOWER FRAME ASSEMBLY

Page 21

5. Locate another 300mm Extrusion and repeat the same procedure

6. Use only 3 - T-Slot Nuts in total, not 4 as above.

NOTE: Use only 3 T-Slot Nuts
LOWER FRAME ASSEMBLY

Page 22

7. Secure with a total of 4 - M5x10mm SHCS and 4 - M5 Washers.

8. To localize during the rest of the build, the extrusion with the 4 - T-Slot Nuts will be the
front of the printer, while the other 300mm Extrusion with 3 - T-Slot Nuts, is the rear.
9. Locate one of the 420mm extrusions and place 4 - T-Slot Nuts into it.

LOWER FRAME ASSEMBLY

Page 23

10. Arrange the front and rear extrusion assemblies to line up with the 420mm extrusion.

11. Secure with 2 - M5x10mm SHCS and 2 - M5 Washers.
12. Repeat for the other side.

LOWER FRAME ASSEMBLY

Page 24

13. Locate another 300mm extrusion and place 2 - T-Slot Nuts inside the side slot, 2 in the
opposite side and 2 in the top slot.

14. Position this extrusion above the front extrusion and secure with 4 - M5x10mm SHCS and 4
M5 Washers.

T-Slot Nut Locations (2 per)
LOWER FRAME ASSEMBLY

Page 25


15. Locate the last 300mm Extrusion and place 3 - T-Slot Nuts into the side slot, 2 in the
opposite side slot, and 2 in the top slot.


Note the locations of the T-Slot Nuts
LOWER FRAME ASSEMBLY

Page 26

16. Position the extrusion above the rear extrusion and secure with 4 - M5x10mm SHCS, and 4 -
M5 Washers.



Reverse View
LOWER FRAME ASSEMBLY

Page 27

17. Gather a 420mm Extrusion and place 4 - T-Slot Nuts in the side slot, and 2 - T-Slot Nuts in
the top slot.

18. Locate the extrusion above one of the side extrusions, and secure with 2 - M5x10mm SHCS,
and 2 - M5 Washers.

Note the locations of the T-Slot Nuts
LOWER FRAME ASSEMBLY

Page 28

19. Repeat for the other side.

20. Lower Frame Assembly Complete, continue onto the Y-Axis Assembly.



Page 29

Y-AXIS ASSEMBLY



Whats Needed?
Tools:
2.5mm Hex Key
4mm Hex Key
6mm Hex Key

Hex Key
Ruler/Measuring Tape
Hardware:
Y-Axis Rail Hardware
Y-Axis Mounting Hardware
Y-Axis Rail and Car Assembly
Borosilicate Glass Plate
G-10 Insulator Plate
Heated Bed
Plastics:
Y-Axis Motor Mount x1
Y-Axis Idler Mount x1
Y-Axis Idler Tensioner x1
Y-Axis Rail Belt Clamp x1
Y-Axis Bed Corner Pieces x4
Section

Y-AXIS ASSEMBLY

Page 30

Steps:
1. Locate a 420mm Extrusion and place 7 - T-Slot Nuts in the top slot, 2 in a side slot, and 2
more in the other side slot.


Note the slot locations for the T-Slot Nuts
Y-AXIS ASSEMBLY

Page 31

2. Locate the Corner Brackets from the Y-Axis Mounting Kit and attach them to the four sides
of the extrusion using the included 4 - M5x10mm SHCS and the installed T-Slot Nuts.

3. Position the extrusion in the center of the printer between the other 420mm Extrusions,
lining up the T-Slot Nuts (not shown) with the bracket holes.

Y-AXIS ASSEMBLY

Page 32

4. Attach the extrusion with 4 - M5x10mm SHCS and 4 - M5 Washers, do not tighten all of the
way.

5. Using a ruler or tape measure, ensure the extrusion is in the center of the printer between
the 420mm extrusions. With a standard MendelMax, this would be 130mm.

6. Tighten the screws and double check the center measurement.
Y-AXIS ASSEMBLY

Page 33

7. Using the Y-Axis Rail as a guide, position the T-Slot Nuts in the extrusion so that they will
be under the holes in the rail.

8. Position the Y-Axis Rail over the extrusion, ensuring that it is in the center of the printer,
between the 300mm Extrusions.

Y-AXIS ASSEMBLY

Page 34

9. Secure with 7 - M5x10mm SHCS and 7 - M5 Washers, but do not tighten all the way.

10. Check the distance, making sure that the Y-Axis Rail is in the center of the printer, between
the 300mm Extrusions, then tighten the screws.


Y-AXIS ASSEMBLY

Page 35

11. Locate the Y-Axis Rail Car and the Insulator Plate. Please Note that the later kits will
include M6 Button Head Screws for the next step.
12. Position the Y-Axis Rail Car under the Insulator Plate and using the 4 - M6x10mm SHCS,
attach the Insulator Plate to the Y-Axis Rail Car. It might be a tight fit, so you might have to
turn each screw a little at a time to get them all of the way in.

13. Gather the Corner Pieces, 4 - M5x16mm SHCS, 4 - M5 washers and 4 - M5 Nuts. These will
be used to attach the Corner Pieces to the Insulator Plate. Note that the Corner Pieces have
a nut trap at the top of them to hold a nut securely while one can turn the screw underneath.


Y-AXIS ASSEMBLY

Page 36

14. Check to see if the M5 Nuts are tight inside the nut traps, if any of them are, line the nut up
with the hole in the corner piece and screw the M5x16mm SHCS from the bottom into the
nut and let it pull the nut into the trap. Remove the screw. Repeat this step for all of the
pieces that are tight.

15. Place a corner piece onto the insulator plate.

Fully seated
Y-AXIS ASSEMBLY

Page 37

16. Gather 2 - M3x10mm SHCS and drop into the smaller holes to the side of the nut trap.

17. Gather 2 - M3 Nyloc Nuts and from the bottom, attach them to the M3 SHCS. Do not
tighten. Note: The corner pieces need a little give in order to enable the bed leveling screws
the chance to move the glass without breaking it. Repeat for the rest of the corners.

Y-AXIS ASSEMBLY

Page 38

18. Fit a M5 Washer over the M5x16mm SHCS and feed through the bottom of the plate up
into an M5 Nut in the nut trap.

19. Test the fit of the glass on the bed. It should be snug and not have any play. If it does, then
you will need to remove the glass and adjust the corner pieces position.

Y-AXIS ASSEMBLY

Page 39

20. Remove the glass from the bed and secure the Heater Element to the glass plate ensuring
that the surface is clean before doing so. Note: The wiring should be routed towards the
back of the frame when mounted on the Y-Axis.

21. Attach the Y-Axis Belt Clamp onto the Y-Axis Rail Car by flipping over the printer
assembly, positioning the belt clamp onto the car and using 4 M3x10mm SHCS.

22. Gather the pieces to build the Y-Axis Tensioner Assembly: Y Idler Tensioner, Y Idler
Mount, 1 - M8x30mm, 2 M8 Washers, 2 608ZZ Bearings.
Y-AXIS ASSEMBLY

Page 40

23. Build the Tensioner as per the photo.


Bolt Head
Bearings x2
Washer
Washer
Nut
Y-AXIS ASSEMBLY

Page 41

24. Attach the tensioner assembly to the mount by slipping 2 M5 Nuts into the slots on the
tensioner. Locate onto the mount, then fasten with 2 M5x10mm SHCS and 2 - M5
Washers.


Nut Slots
Y-AXIS ASSEMBLY

Page 42

25. Attach the assembly to the front of the frame with 2 M5x10mm SHCS and 2 M5
Washers into the captured T-Slot Nuts.

26. Trap an M5 Nut in the assembly and secure with 1 M5x10mm SHCS. This will serve as the
Y-Axis Tension Adjustment Screw.


Y-AXIS ASSEMBLY

Page 43

27. Gather the Y Motor Mount, 2 M5x10mm SHCS, and locate the mount on the rear of the
frame. Secure using the hardware into the T-Slot Nuts that are trapped in the frame
extrusion. Note the orientation of the mount.

28. Attach one of the NEMA 17 Motors to the mount using 2 - M3x10mm SHCS, 2 M3
Washers. Note: I routed the wires so they will go under the frame.


Y-AXIS ASSEMBLY

Page 44

29. Locate the GT2 Pulley and secure it onto the motor shaft, ensuring that it is flush with the
tip. Use the included 1/16 hex key.

30. Locate the GT2 belt and test route it. See PHOTO for routing.


31. Secure it with Zip Ties.
Start Here
Around the motor shaft
Around the Idler
End Here

Page 45

UPPER FRAME ASSEMBLY



Whats Needed?
Tools:
3mm Hex Key
4mm Hex Key
T-20 Torx Key
Hardware:
M5x10mm SHCS x28
M5 Washers x24
M5x10mm FHS x4
T-20 Self Tapping Blind Screws x4
T-Slot Nuts x24
340mm Extrusion x4
420mm Extrusion x2 (Drilled)
Plastics:
Bottom Vertexes Upper Left x2
Bottom Vertexes - Upper Right x2
Top Vertexes x4
Z- Top Vertex for 10mm Rods x2
Section

UPPER FRAME ASSEMBLY
Page 46

Steps:
1. Gather the 340mm Extrusions, 2 Bottom Vertex Upper Left and 2 Bottom Vertex
Upper Right pieces, and 4 M5x10mm SHCS.
2. Begin by placing a washer onto a SHCS and locating it into the hole on the one of the
vertexes, see photo.

3. Tighten the screw all of the way.

Screw
UPPER FRAME ASSEMBLY
Page 47

4. Repeat for all of the extrusions and vertexes.

5. Locate the other holes on the vertex. Now slide 2 T-Slot Nuts, into the slots so that you
can secure the vertex through the other holes into the extrusion. See PHOTO.

UPPER FRAME ASSEMBLY
Page 48

6. Repeat this for the rest of the assemblies. In total, you will need 8 T-Slot Nuts, 8
M5x10mm SHCS, and 8 M5 Washers.

7. Attach one of the assemblies to the Lower Frame with 1 M5-10mm FHS, and 1
M5x10mm SHCS with 1 M5 Washer. Note Do not tighten all of the way. Repeat for the
rest of the vertexes. Use a 3mm Hex Key for M3 FHS.

UPPER FRAME ASSEMBLY
Page 49

8. Locate the 4 Self Tapping Blind Screws and fasten them to the top end of the 340mm
Extrusions. Use a T-20 Torx Key.

9. Trap 2 T-Slot Nuts into each 340mm Extrusion before you mount the 420mm Extrusion
onto the ends using the blind screws. Note: Do not tighten.

Trap two T-Slot Nuts
before sliding the top
extrusions on
UPPER FRAME ASSEMBLY
Page 50

10. Trap 4 T-Slot Nuts into the front slot of the front 420mm Extrusion, 4 T-Slot Nuts into
the rear slot of the rear 420mm Extrusion, and if using the Optional Spool Holder that is
offered, then stick 2 T-Slot Nuts into the tops of these extrusions as well.

11. Locate the 2 - Top Vertex for 10mm Rods. These will be installed on the 420mm Extrusions
using 4 M5x10mm SHCS and 4 M5 Washers. Do not tighten.


T-Slot Nuts Locations are marked, visible locations in
blue and unseen locations in green.
UPPER FRAME ASSEMBLY
Page 51

12. Locate the 4 Top Vertexes. Mount these on the corners of the 340mm and 420mm
Extrusions using 8 M5x10mm SHCS and 8 M5 Washers per vertex. Do not tighten.

13. Tighten the M5x10mm FHS that are in the Lower Frame, such that the vertexes are as
square as possible.

Also, tighten the M5x10mm SHCS that is on the same vertex, again, making sure that
nothing goes out of square as you are tightening. Repeat for all of the Lower Vertexes.

Square
M5x10mm
SHCS
UPPER FRAME ASSEMBLY
Page 52

14. Take a measurement at the top of these vertexes. It should be 260mm. Take a measurement
at the bottom edge of the top vertexes. It should be 260mm, or at least match the above
measurement.

15. If it doesnt match, loosen the blind screws and adjust the 340mm extrusions back and forth
until it does match.

16. Tighten the blind screws through the extrusion holes once everything is square.
17. Repeat steps 15-16 for the other side.
Adjust these extrusions
UPPER FRAME ASSEMBLY
Page 53

18. Tighten the Upper Vertexes so that their edges are parallel with their respective extrusions.



Page 54

EXTRUDER ASSEMBLY



Whats Needed?
Tools:
4mm Hex Key
6mm Hex Key
2.5mm Hex Key
3mm Hex Key

Hex Key
Hardware:
Extruder Hardware Kit
LulzBot Budaschnozzle 1.1
Plastics:
Idler Holder x1
Small Gear x1
Large Gear x1
Groovemount Holder x1
Notice:
Not all extruder and hotend combinations are created nor assembled equal. The extruder that I am
using is a jonaskuehling retake on Gregs/Wades Extruder. It can be found here:

http://www.thingiverse.com/thing:18379

My hotend is a Lulzbot Budaschnozzle 1.1 with 0.5mm tip.

The Extruder Hardware is the additional kit offered by TrinityLabs.
Section

EXTRUDER ASSEMBLY

Page 55

Steps:
1. Locate the Extruder Plastic Parts and Hardware kit.
2. Take the Extruder Groovemount piece and insert a 608ZZ Bearing into the cutouts.

3. Locate the Idler Holder, 1 - M8 Stud, and 608ZZ Bearing.
4. Place the bearing over the stud and press inside the idler holder.

EXTRUDER ASSEMBLY

Page 56

5. Attach the Idler Holder Assembly onto the Groovemount piece with 1 - M3x35mm SHCS
and 1 - M3 Washer.


EXTRUDER ASSEMBLY

Page 57

6. Locate the Hobbed Bolt. Depending on the location of the grooves on the bolt, you might
need to pad it with washers when you insert it through the two bearings. As it turns out. I
did not have to. I have marked the location of where you might have to locate the washers in
the photo.

7. Of course, if the hobbing is past the hole to the right (closest to the head of the bolt)
without any washers, the hobbed bolt will not work.
Look for
alignment
here
adjust with
washers here
EXTRUDER ASSEMBLY

Page 58

8. Place 2 - M8 Washers on the end of the bolt. These will be adjusted when the small gear is
placed on the motor.


EXTRUDER ASSEMBLY

Page 59

9. Locate 1 - M8 Nut and secure it into the nut trap in the Large Gear. Place the gear on the
end of the bolt. Tighten it up so that the bolt will spin with the bearings, but not loosen the
nut and subsequently, the large gear. If this happens, tighten it more.

10. Place 2 - M4 Nuts into the nut traps on the top of the assembly.

EXTRUDER ASSEMBLY

Page 60

11. Attach 2 - M4x55mm SHCS into the holes, through the nuts, deep enough to hold, but not
all the way.

12. Attach the Small Gear onto a NEMA 17 Stepper Motor, leaving 2-3mm of space between
the housing and the bottom of the gear and ensuring that the flat of the shaft is facing the
hole in the side of the gear.

EXTRUDER ASSEMBLY

Page 61

13. Place a nut into the nut trap on the gear and secure it to the shaft, using 1 - M3 Set Screw.
14. Attach the motor onto the main assembly so that the alignment of the gears can be checked
with 1 - M3x10mm SHCS.

15. Using 6 - M8 Washers between the large gear and the main assembly, align the gears.

EXTRUDER ASSEMBLY

Page 62

16. Using 2 - M3x10mm SHCS, finish attaching the motor to the main assembly.

17. Check for proper gear meshing and if it is not correct, loosen the screws that hold the motor
to the assembly, move the motor towards the gear, and tighten the screws back up.
Attach screws
marked
Ensure proper
meshing of
gearing

Page 63

X-AXIS ASSEMBLY



Whats Needed?
Tools:
4mm Hex Key
Hardware:
M5x10mm SHCS x8
M5 Washers x8
M5 Thin Nuts x8
8mm Self Aligning Bronze Bushings x8
10mm Self Aligning Bronze Bushings x4
8mm Precision Chromed Shafts x2
10mm Precision Chromed Shafts x2
Delrin Leadscrew Nuts x2
Precision Leadscrews x2
Plastics:
X-Carriage for Bronze Bushings
X-End Motor Side for 10mm Shafts
X-End Idler Side for 10mm Shafts
X-End Motor Side Clamp
Section

X-AXIS ASSEMBLY
Page 64

Steps:
1. Locate the X-Axis Carriage, and all of the 8mm and 10mm Self-Aligning Bronze Bushings.
2. Using a suitably sized piece of rod, insert into the bushings and with a pair of pliers, or an
adjustable wrench, rock the bushing around until it is loose in its holder.

3. Repeat for all of the other bushings.
4. Press the bushings into the carriage. (One is intentionally missing from the photo.)

5. Insert 1 - 8mm Precision Chromed Steel Rod and move the carriage back and forth until the
movement is smooth. Remove the rod.
Move the rod so that it moves the bearing throughout its entire range of motion
X-AXIS ASSEMBLY
Page 65

6. Repeat for the second 8mm rod. Note: In photo the carriage IS upside down.

7. Locate the X-Axis Motor End and Clamp. Trap 2 - M5 Nuts into the bottom of the motor
end and secure with 2 - M5x10mm SHCS. (Screws are not inserted in the photo)

Arrows show where screws go
X-AXIS ASSEMBLY
Page 66

8. Insert both rods, and secure the clamp to the rods, using 4 - M5x10mm SHCS, 4 - M5
Washers , and 4 - M5 Nuts. The nuts are trapped inside the nutraps in the bottom of the
clamp.

9. Locate the X-Axis Idler End, 1 - Delrin Nut, 2 - M5x10mm SHCS, 2 - M5 Washers, and 4 -
8mm Self-Aligning Bronze Bushings. Insert the bushings into the end, and secure the delrin
nut onto the end as well using the screws.

Arrows show where screws go
Bushing
locations,
green are
not seen in
photo.
X-AXIS ASSEMBLY
Page 67

10. Locate the other Delrin Nut and secure it with 2 - M5x10mm SHCS to the X-Axis Motor
End.


X-AXIS ASSEMBLY
Page 68

11. Locate the 4 - 10mm Self Aligning Bronze Bushings and press two into the X-Axis Motor
End and two into the X-Axis Idler End.

12. Set aside and continue with the Z-Axis build up.
10mm Bushings go here
as well as under the
ends

Page 69

Z-AXIS ASSEMBLY



Whats Needed?
Tools:
2.5mm Hex Key
3mm Hex Key
4mm Hex Key
6mm Hex Key

Hex Key
Spirit/Bubble Level
Hardware:
NEMA 17 Stepper Motor x3
M3x10mm x12
M3x16mm x4
M3 Washers x16
M4x18mm SHCS x2
M4 Washers x2
M4 Nuts x2
M5 Nuts x12
M5x10 SHCS x16
M5 Washers x8
M8x30mm SHCS x1
M8 Washers x3
M8 Nuts x1
Leadscrew Couplers x2
10mm Precision Chromed Shaft x2
GT2 Pulley x1
GT2 Belt x1
Plastics:
Z-Axis Rod Clamps x4
Z-Axis Motor Mounts x2
Z- Lower Motor Mount Support (A)
x2
Z- Lower Motor Mount Support (B)
x2
X-Carriage Belt Clip x2
Section

Z-AXIS ASSEMBLY
Page 70

Steps:
1. Locate one of the Z-Axis Motor Mounts, a NEMA 17 Stepper Motor, and attach the motor
mount onto the motor with 4 - M3x10mm, and 4 - M3 Washers. Do not tighten. Also,
insert the 4 - M5 Nuts into the traps in the mounts.

2. Locate 2 - Z-Axis Motor Mount Legs and attach to the motor mount with 2 - M5x10mm
SHCS and 2 - M5 Washers.

Arrows show where the
nuts go
Z-AXIS ASSEMBLY
Page 71

3. Attach the motor mount assembly to the right side of the frame with 4 - M5x10mm SHCS
and 4 - M5 Washers. Do not tighten.

4. Repeat steps 1-3 with the other mount and attach to the left side of the frame.
Z-AXIS ASSEMBLY
Page 72

5. Locate 1 - Leadscrew Coupler, and attach to the motor using a 3mm hex key as a spacer
between the coupler and the motor.

6. Repeat for the other motor.
7. Locate the X-Axis Assembly, 1 - 10mm Precision Linear Shaft, 4 - M5x10mm SHCS, 2 - Z-
Axis Rod Clamps.
Z-AXIS ASSEMBLY
Page 73

8. Place the X-Axis Assembly on the Y-Axis Table.

9. Position the shaft such that it is fitted into the Z-Axis Top Vertex, securing it with the Z-
Axis Rod Clamp and the SHCS and WASHERS.


Z-AXIS ASSEMBLY
Page 74

10. Position the bottom of the shaft such that it is in line with the motor mount assembly, and
loosely fasten the rod clamp with the screws and washers.

11. Align the shaft such that it is parallel with the frame, if looking from the front: Adjust the Z-
Axis Top Vertex in and out of the extrusion to get it even. Tighten the screws when
complete.

Move the top vertex to adjust
Z-AXIS ASSEMBLY
Page 75

12. If looking from the side: Adjust the Z-Axis Motor Mount Assembly from side to side along
the extrusion in order to get shaft straight. Tighten down the screws when complete.

13. Repeat for the other side.
14. Check the smoothness of travel in the Z direction by lifting the X-Axis Assembly up along
the shaft, taking care not to push through a bind. If this happens, lower the assembly to the
bed, and make an adjustment to the Z-Axis.
Move the
motor mount
to adjust
Z-AXIS ASSEMBLY
Page 76

15. Locate the Precision Leadscrew and start screwing them into the top of the X-Axis Motor
Ends Delrin Nut until you reach the Z-Axis Motor Coupling.

16. Adjust the motor back and forth in order to capture the leadscrew end, bottoming it out.

Z-AXIS ASSEMBLY
Page 77

17. Tighten the set screw in the coupling to secure the leadscrew onto the motor. Be careful not
to put any undue stress onto the X-Axis.
18. Repeat 16-18 with the other leadscrew.
19. Check to see if the leadscrew is parallel with the linear shaft. Adjust it by moving the motor
inside the motor mount back or forth. Tighten the screws once adjusted.

20. Repeat the above step with the other side.

Tighten motor
mount screws
once adjusted
leadscrew is
parallel with
the rod.
Z-AXIS ASSEMBLY
Page 78

21. Ensure that the X-Axis is parallel with the Y-Axis Table by adjusting one of the leadscrews
up or down.

22. Gather 1 - M8x30mm SHCS, 3 - M8 Washers, and 1 - M8 Nut.
23. Arrange the hardware as shown in the photo.

Adjust leadscrews by hand to
raise or lower x-axis

Z-AXIS ASSEMBLY
Page 79

24. Thread the bolt onto the X-End Idler Side, and secure with the washer and nut as shown.

25. Take the last NEMA 17 Stepper Motor and attach the GT2 Pulley to the shaft with the set
screw included with the pulley.

Z-AXIS ASSEMBLY
Page 80

26. Attach the motor assembly to the X-End - Motor Side with 4 - M3x10mm SHCS and 4 - M3
Washers.


Z-AXIS ASSEMBLY
Page 81

27. Using the X-Axis GT2 Belt, 1 - Belt Clip, 2 - M3x16mm SHCS, 2 - M3 Washers, and 2 - M3
Nuts, attach the belt to the X-Carriage on the motor side. Use the nut traps on the underside
of the carriage.

28. Route the belt from the bottom of the motor, around the GT2 Pulley. Continue routing
across to the idler.

Z-AXIS ASSEMBLY
Page 82

29. Secure to the other side of the X-Carriage with 1 - Belt Clip, 2 - M3x16mm SHCS, 2 - M3
Washers, and 2 - M3 Nuts. Remember to tighten the belt so it is taut.


Z-AXIS ASSEMBLY
Page 83

30. Ensure proper alignment of the pulley and idler by moving the carriage back and forth. If
they are misaligned, adjust the position of the belt under the belt clips so that they are closer
or farther from the center of the x-carriage.

31. Place 2 - M4 Nuts into the nut traps on the Extruder flange.

Looking down the belt, make
sure that the top run is in line
with the bottom run
Z-AXIS ASSEMBLY
Page 84

32. Place the hotend on top of the x-carriage.

33. Place the extruder on top of the hotend, note orientation.

34. Using 2 - M4x18mm SHCS, and 2 - M4 Washers, attach the assembly together, but do not
tighten it.
Z-AXIS ASSEMBLY
Page 85

35. Using a scrap piece of filament that matches the size of the hot end that you are using,
thread it through the extruder.

36. The filament will be used to line the hotend with the extruder for a smooth transition. Move
the extruder back and forth while pulling and pushing on the filament. When you feel little
or no resistance, tighten the screws.
A note regarding the method of securing the idler hinge to the main body. Some people use
washers, or springs to provide tension onto the idler. I used a combination of lockwashers,
flats and spacers.

PLEASE NOTE: Due to the fact that the community requires this documentation ASAP, I will not
be including the Electronics nor Calibration sections in the initial release. I will follow up with a
second revision that includes these sections.