1. Extruder Assembly - kinematicdigit/Jabberwocky GitHub Wiki
At this stage you should have all the pre-requisites required to start building the Jabberwocky toolhead.
[!NOTE] As you build, we use some terms to describe the various orientations of the assembly to insert things correctly. We use the latch-side to describe the lever that is used to unhook the Jabberwocky for servicing. While hinge-side will be used to describe the side of the assembly where the extruder pivots.
If you haven't already, please download and install Autodesk Fusion 360 and open the CAD model. Alternatively, if you're more familiar with other CAD software like SolidWorks or Shapr3D, you can use the provided STEP file.
Extruder
To begin the assembly, we’ll start by installing the heat inserts into the Motor Mount printed part as illustrated in the image below.
Next, preload the four LDO T-Nuts as shown in the image below. They should be centered on each circular cutout where the screws will be attached, as shown in the image on the right.
Next, install the MR84-ZZ bearing into the mid-body using the printed tool. The tool is designed to apply even pressure and prevent the bearing from being inserted further than necessary. Temporarily use any full-threaded M3x35 or longer screw from the kit (partially threaded screws are not recommended), along with an M3 hex nut, to secure the bearing in place through the two-piece printed tool. Then, remove the M3x35, printed tools, and M3 nut.
IT IS CRITICAL that the bearings are aligned flush to the boss of each of the receiving holes. If they are not flush, remove and inspect the holes for any debris or filament.
Next, insert the M4x18mm metal dowel, LDO PEEK sleeve bearing, and the non-threaded Orbiter gear. Double-check that everything is aligned correctly, as any misalignment will prevent the Motor Mount from sitting flush. The image on the right shows the bearing in place.
Next, install the BondTech compound drive gearon the Motor Mount. Insert the M4x18mm dowel from the back, then slide the BondTech drive gear into position, making sure the dowel passes through as you do. Install the second MR84-ZZ bearing, ensuring a push fit just as we did in the previous step.
Next, attach the mid-body and motor-mount together, ensuring the gears are properly aligned and the M4x18 dowel is ALIGNED. Use two Stainless Steel M3x10 BHCS to secure the pieces together and tighten. Remove the bottom rubber part of the ECAS fitting and push-fit it into the top of the Mid body. Then, take one 6x3mm N52 magnet and push-fit it into the side of the Mid body. For added security, you can apply a small dab of superglue to prevent it from slipping out during operation. This is a good time to check that the gears are smooth and with some filament. Make sure the drive gear and the orbiter gear is not feeling too loose (this can be checked by holding the orbiter gear still, and turning the drive gear. There should be some backlash between these gears, but if it is really loose, then take it apart and reassemble, ensuring the bearings and dowels are all seated properly).
Next, we’ll assemble the Guidler. Begin by inserting the LDO PEEK sleeve bearing into the second *non-threaded Orbiter gear. Then, align the gear with the slot on the Guidler and secure it in place using the M4x16 dowel pin. Finally, install the M3x6 FHCS, tightening it until it sits flush with the surface of the Guidler—this screw will later be used to adjust the grip.
Next, attach the Guidler to the extruder using an M3x20mm socket head cap screw (SHCS) as shown below. Now install the LDO Tensioner, which will screw into the LDO T-Nut we pre-installed earlier. This completes the extruder assembly.
Finally, insert the F682X-ZZ filament guide bearing into the bottom of the extruder through the cutout, as shown below.
This concludes the Extruder Assembly section.