QC Diameter Sensor - TechforTrade/Thunderhead-Filament-Extruder GitHub Wiki

Note: The Non-contact Diameter Sensor has its own repository. This page mainly describes how to make the mounts needed to use it as the QC diameter sensor. Go to the Non-contact Diameter Sensor wiki for documentation on how to build it.

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Image	Name	Description	Source	Files	Qty
	Support for QD Dia Sensor		Made		1
	Non-contact Diameter Sensor		Made	step	1
	Mounting Clamp A		Printed	stl, step	1
	Mounting Clamp A_1in		Printed	stl, step	1
	Mounting Clamp B With Roller Supports		Printed		1
	Mounting Clamp B_1in		Printed	stl, step	1
	Roller		Printed		2
	Thumb Nut 1-4 in Small		Printed	stl, step	1
	Bearing 104ZZ		Purchased		4
	Hex Bolt 1-4 in by 2-1-2 in long		Purchased	step	1
	Nut 1-4 in		Purchased	step	1
	Nut M3		Purchased	step	8
	Nylock Nut M4		Purchased		2
	Socket Cap Screw M3 by 40 mm long		Purchased	step	8
	Socket Cap Screw M4 by 45 mm long		Purchased		2
	Washer 1-4 in		Purchased	step	1
	Washer M3		Purchased	step	8
	Washer M4		Purchased	step	4

Item No.	Image	Name
1		Allen Key 2.5 mm
2		Pipe - short piece
3		Vise
4		Wrench 5.5 mm
5		Wrench 7-16 in

Go to Making the QC Diameter Sensor Parts for information on how to build the following parts:

• Support for QD Dia Sensor
• Non-contact Diameter Sensor

Step 1: Press M3 nuts into the mounting clamps. An easy way to do this is the insert a 20 mm socket cap screw into the bolt hole and then screw it onto the nut. By tightening the screw onto the nut, the nut will be drawn into the nut trap. Use a vice to press the 1/4 in. nut into the end of the mounting clamp that has a 1 inch groove.

Step 2: Press a 1/4 in. bolt into the thumbnut using a vice (or hammer with light blows) and a short piece of pipe. Add a washer to the bolt and use it to couple the two mounting clamps as shown.

Step 3: Press the four 104ZZ bearings into the ends of the rollers using a vice.

Step 4: Attach the rollers to the mounting clamp with roller supports using M4 bolts, washers, and nylock nuts.

Step 5: Place the non-contact diameter sensor into the groove in the mounting clamp with the 3/4 in groove in the orientation shown (note the side that the wires will come out). Secure it the mounting clamp that has roller supports, four M3 socket cap screws and washers.

Step 6: Secure the other clamp to the mounting bar with the other 1 in mounting clamp, four M3 socket cap screws and washers.

The QC diameter sensor is now complete.

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• By Benjamint444 - Own work, CC BY-SA 3.0, Link
• Zephyris at the English language Wikipedia [GNU]