Prusa i3: Graber edition: frame assembly

Once all the parts are lasercut it's time to assemble.  First, lay out all the parts.  I'm using a non-stick mat (slightly stained...) to keep screws/nuts from bouncing all over.  Small tupperware bins help keep the itty bits organized.


I took videos most of the time.  These are real-time; later I'll go back and make a condensed version, keeping only the essential steps.

Layout all of the parts

Assemble the Z Motor mounts & the frame

Assemble the base of the machine

Coffee is essential to any build process.  I'm doing this at 7 in the morning on a Saturday - while baby Scarlet sleeps in.

I didn't do much prepwork on this... some foibles included.  Assembling the front and the rear, including the Y axis motor and idler mounts.

 

 

 

 

 

 

 

Final frame pieces - the upper Z rod mount!

 Frame Complete!  If you have any questions, or want photos of  particular assembly let me know.

Prusa i3: Graber edition: lasercutting

Once the plywood was stained, I waited three days to make sure it was well and truly dry.  Then, LASER.

I'm using the laser cutter at nova-labs.org.  It's a 100 watt Hurricane Laser.

First Plate - this is the frame, X and Y axes, bed, motor mounts...

Second plate - this is two bases, and two LCD mounts.

The files are color-coded for cut order and intensity.  If you cut a part out completely, you can no longer cut inside of it - so you need to cut out the insides first, then the next border, then the next... etc.

If you look closely, the green hexagons are nut traps - meant to be cut halfway through the material.

The Raw lasercut files are in my Google Drive folder.  The dxf's are the parts, the rest are probably only applicable to Nova-Labs' laser.

You'll want to test the cut speed and power of your laser - I made a test set for cutting all the way through, cutting halfway through for the nut traps, and labeling. 

MY CUT ORDER

1. Red - speed 100, power 10 - these are the labels, just etching
2. Green - speed 30, power 50 - nut traps - cut halfway for nut traps
3. Black - speed 9, power 100 - all the screw holes/tiny stuff
4. Blue - The rest are all the nested parts.
5. Magenta
6. Teal
7. Yellow

You can use the cut order on any laser, but should adjust the speed and power settings.

Prusa i3: Graber edition: staining

Once the plywood arrived, I started to stain it.  This isn't purely cosmetic - I think it's an important step when building anything out of wood.

Untreated wood will swell and warp over time - especially plywood.  Because I had so many small pieces to be lasercut, I decided to stain first.

Underneath the panels is a non-skid pad for carpet.

Staining:

• Get everything ready.
• Gloves!
• stain
• stirrer
• opener
• trim tray
• brush - I like the foam ones
• paper towels
• wood!
• Put on your gloves, open the stain
• Spread stain on thin and quick - you want full coverage.
• Wait 5 mins - or just do three panels in sequence
• You'll need one and a half panels per printer.
• Wipe off excess stain with the paper towels - you want the wood grain to show through.
• Move panels off to the side, let dry 3 hours.
• When dry, rub with fine steel wool
• Apply a second coat.
• Now do the other side.

When you're done with a side, you can grab the foam part of the brush with your glove, and then take the glove off over the brush - sealing the wet paint inside and saving it for the next coat.

The red is called gunstock - I really love this color.  The black shows the panels after one coat, and then standing up to finish drying before lasercutting.