3. Lower Toolhead - kinematicdigit/Jabberwocky GitHub Wiki
Next, we’ll begin assembling the lower toolhead, which houses the printer hotend, fans, and hotend LED.
Begin by installing heat-set inserts into both the Shroud Body and the Conch Mount. Lay the Shroud Body face-down and carefully drop the heat insert into position. Due to limited space, a standard heat-set tip cannot be used here—gently press the insert in using the side of the soldering iron.Take your time to ensure the insert sinks in evenly and does not tilt. Use the same method to install the insert in the Conch Mount. (this has been changed to a drop in nut in the latests builds).
Next, we'll install the LEDs that illuminate the hotend. Start by placing the pre-wired Neopixel LEDs into the Dual Neo Holder. To ensure a proper fit, gently bend the wires at the center so the LEDs can drop cleanly into their designated slots.
Bundle wires to the latch-side of the toolhead. Carefully route the wires into the cable channels, as the fans will be installed in front of them, and space will be limited.
Next, install the 2510 axial hotend fan. This is a push-fit component (be careful with the fan grills as they break easily with installation or servicing) and should be oriented so the wiring exits to the latch side, aligning with the designated cutout. Carefully route the wires through the cable channel, as the part cooling fan will later enclose them.
Click for wiring image details
Axial hotend fan wire install
Then, install the M3x25 SHCS screw, which is used to latch the extruder to the lower toolhead body. This is located on the latch side of the shroud and into the T-nut located above the part fan 1 bay.
Proceed with installing the two 3010 DC blower fans. These slide into their respective slots with the blower outlets facing downward.
- For the latch-side fan (parts fan 1), route the wiring internally alongside the 2510 axial fan cables (you can also add a little Kapton tape to hold it in position)
Click for wiring image details
parts fan 1 wiring detail
Push down on the wire to ensure it sits properly at the back, and also towards the left of the channel to make sure the fan is fully inserted.
- For the hinge-side fan, install it with the wiring facing outward.
Click for wiring image details
parts fan 2 wiring detail
Finally, install the fan grill.
This is a push-fit part that clips into the four screw holes on the front of the 2510 axial fan.
Next, insert two LDO T-nuts into the Conch Mount, ensuring the screw holes are properly aligned. Ensure the two sets of wires are pulled out of the Conch channel; they will route under and outside of the plastic mount. ~~ Route the wire through the V80 conch mount so it comes out through the top and channelling leads to the right.
Click for wiring image details
conch wiring example
Push down on the wire to ensure it is sitting in the back, and also towards the latch-side of the channel to ensure the insertion of the fan goes all the way in.
Carefully slide the Conch Hotend into position, making sure the wires are folded neatly to the side so they can later be secured to the Shroud housing with a cable tie. Secure the hotend using two M2.5x8mm SHCS in the two lower holes of the mount.
Note
A late edition update was adding M2.5x8 screws to the lower portion of the Conch Mount. The nuts are still needed for those that have Batch 1 kits as the screws are not in that kit. Use as instructed below. The latest build eliminates the need to use drop-in T-nuts and top mounting screws, making them redundant and unnecessary. The two M2.5 screws also make it much easier to remove the hotend if needed.
Click for wiring image details
hotend wiring install
Next, insert the pre-cut 15mm Bowden tube into the top of the Shroud, ensuring it is fully seated. If necessary, use a hex bit to press it down evenly for a snug and secure fit.
To complete the toolhead assembly, we’ll now join the extruder with the lower section of the toolhead.
First, slide the F682-ZZ bearing over the 15mm Bowden tube. If it doesn’t fit, ensure the Bowden tube is fully inserted or trim it.
Next, align the top and bottom halves of the toolhead. Slide the lower body latches into position so they hook onto the long button head cap screw (BHCS) that secures the filament cutter. Once aligned, seat the top half of the toolhead horizontally and lock it in place using the lever lock.
Expand to view final wiring arrangement
Final wiring arrangement
This completes the physical assembly of the Jabberwocky toolhead.
