Top interface

Step 1 Attach the interface ribs to the upper fixed section

Attach the Interface rib (switch gap) to the Interface upper fixed section, two positions counterclockwise of the notch for the stepper mount. Use two screws tapping directly into the plastic.

Attach the remaining 5 Interface ribs to the Interface upper fixed section, two screws each, again tapping into the plastic.

Slot the Interface NEMA 23 bracket into the Interface upper fixed section and secure it with a screw from below.

Attach the whole assembly to the bottom of the Top plate with screws through holes S2 and S3 into the Interface NEMA 23 bracket.

Step 2 Prepare the interface brackets

Align an Interface bracket with piece E (Interface spoke, long) of aluminum extrusion.

Place T-nuts in the extrusion, lined up with the 4 holes on the side of the Interface bracket.

Slide the extrusion into the Interface bracket, careful not to dislodge the T-nuts, and screw them in.

Repeat for all 6 Interface brackets.

Step 3 Prepare the limit switch interface bracket

Push the Printed dowel pin into the Limit switch housing.

Attach a Roller lever limit switch with 2 screws so the roller sits next to the dowel pin.

Align the switch housing with the extrusion of one of the prepared Interface brackets so the limit switch is on the same face as the sloped side of the bracket. Slide 2 T-nuts into the extrusion and screw the Limit switch housing to the extrusion. Slide it as far toward the Interface bracket as possible for now; it gets aligned properly later.

Step 4 Install the brackets

Slide a T-nut just into the end of the extrusion of the limit switch interface bracket. Slide the extrusion into the Interface rib (switch gap) and Interface upper fixed section, securing it loosely with a screw. Slide the extrusion slightly in and out to align the holes on the Interface bracket with the holes on the Top plate, then tighten the screw.

Repeat with the 5 other prepared Interface brackets into the 5 other Interface ribs.

Flip the whole assembly and screw all 6 Interface brackets into place through holes I1 to I6 and O1 to O6.

Step 5 Prepare the interface chute gear and mount

Slot the Limit switch hammer into the Top interface chute mount, then screw it in place from below.

Align the Chute gear on the Top interface chute mount with the notch by the screw for the Limit switch hammer. Attach it with 5 screws.

Align the Top interface lazy Susan washer with the 4 inner heat inserts on the Top interface chute mount. Align the inner ring of the Lazy Susan with these 4 heat inserts too. Screw the Lazy Susan into position through the washer and into the Top interface chute mount.

Once complete, the free section of the Lazy Susan should rotate freely.

Step 6 Attach the interface chute to the assembly

Place the Interface big spacer on the Interface upper fixed section with its 4 holes lined up with the 4 heat inserts.

Rotate the free part of the Lazy Susan on the assembled interface chute so that 3 of its holes line up with the holes in the Top interface chute mount. Place the assembly on top of the Interface big spacer with the 3 holes aligned with 3 of the heat inserts. Screw these together tightly.

Rotate the Top interface chute mount 90 degrees relative to the Interface upper fixed section to reveal the 4th screw hole in the Lazy Susan (it should also line up with a hole in the Interface big spacer and a heat insert). Drive a screw tightly through this hole.

Once done, check that the chute rotates freely relative to the Interface upper fixed section.

Step 7 Adjust the limit switch

Loosen the screws attaching the Limit switch housing to the extrusion. Slide the housing so the Limit switch hammer rotates into place between the Roller lever limit switch and the Printed dowel pin in both directions of rotation. The switch clicks when it is being activated correctly. Avoid friction between the Limit switch hammer and the Printed dowel pin. Tighten the screws to keep the housing in this position.

Step 8 Install the chute stepper motor

Slide the prepared Timing pulley over the shaft of the NEMA 23 stepper motor and tighten the two worm screws on its side. Slide the Interface spur gear onto the Timing pulley and secure it with 5 screws, half tapped into the Interface spur gear and half bracing against the Timing pulley.

Push a 608 2RS bearing into the Interface idler gear.

Push the idler gear onto the Interface NEMA 23 bracket with the bearing facing outwards and secure it with a button head screw (the video uses a screw with a washer).

Slot the NEMA 23 onto the Interface NEMA 23 bracket and secure it with 4 screws.

At this point the chute should still rotate, but you will now feel resistance from the stepper motor.

Step 9 Attach the cable cage top

Slot the Cable cage top over the Top interface chute mount, with the corners of the hexagon aligning with the Interface brackets.

Place the Cable cage bracket (cable mount) on the Interface bracket opposite the Limit switch housing (this minimises the maximum travel of the cable). Screw it into the Interface bracket, clamping down the Cable cage top.

Screw the other 5 Cable cage brackets down over the other 5 corners of the Cable cage top.

Step 10 Put the cable in the cable cage

Place a nut into the bottom of the Cable clamp (outer) (the video skips this), then push it into the recess in the Top interface chute mount. Fasten it with 2 screws.

Rotate the chute until it hits the limit switch.

Fold your IDC ribbon cable around the Cable clamp (inner), following the guides on the clamp. Slide the cable and clamp together into the Cable clamp (outer), leaving a significant tail to connect to the chute.

Guide the rest of the ribbon cable around the side of the Top interface chute mount, in the direction the chute can rotate, back to the Cable cage bracket (cable mount).

Screw the Ribbon cable clamp lightly to the Cable cage bracket (cable mount), clamping the ribbon cable between the two.

Check that the chute can rotate fully to the limit switch in both directions, then tighten the Ribbon cable clamp screw. Use a long screw through the Cable clamp (inner) into the nut in the bottom of the Cable clamp (outer) to secure that end (the video uses a different type of screw here).

Step 11 Attach the cable cage bottom

Place the Cable cage bottom over the Top interface chute mount. Use 6 nuts and bolts to clamp the Cable cage bottom, Cable cage top, and Cable cage brackets together.

After this step the chute should still rotate to each of its limits.

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Steps for mounting the full interface frame are coming.