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Assembled extruder with heatsink and 24 VDC fan, side view.
Be sure to use a 40 x 40mm 24 VDC fan. MBI uses approximately a 5 CFM fan, but you can get much better, quieter fans which move more air (higher CFM). The fan shown is approximately 7 CFM. Note arrows molded into the side of the fan and orient the fan such that it blows towards the heatsink.
The X endstop switch (green & black wires, right edge of carriage) has only the common (C) and normally open (NO) contacts wired. These two wires will be routed back to a Makerbot v1.2 endstop PCB which has had its switch removed. REMOVE the switch from the PCB to prevent shorting the 5V and ground rails. Note that the normally closed (NC) contact is not wired. On the endstop PCB it is only used with the LED indicator circuit; it is not essential to the endstop's operation.
Note also that the endstop switch is here affixed with a wire tie. It is also possible to use two 2-56 bolts. The head of at least one bolt -- the one closest to the linear bearing -- must be on the underside of the carriage; otherwise, the bolt will interfere with the bearing.
Top view of the heater block mounted to the heat spreader bar and XY plate. The top of the thermal barrier tube should not project above the M6 hex nut. Try to keep the sides of the M6 nut parallel to the long edge of the heat spreader bar. This helps prevent interference with the face of the extruder stepper motor.
Makerbot Mechanical Endstop v1.2 with the switch removed and replaced with a two position screw down terminal post occupying the Common and Normally Open (NO) pads.
Left: Maximum build size on a MakerBot Replicator 1: 150mm
Right: Near maximum build size on the Unofficial ReplicatorXL: 248mm (I think it can go to 255 or so)
Custom Replicator case increases build height by 100mm.
New 400mm rods, but the stock Z-axis threaded rod is long enough. Custom Replicator case increases build height by 100mm.
Almost 10" tall print - 248mm to be exact - my tallest MakerBot print by a mile. I think I can go to 255 total now? Custom Replicator case increases build height by 100mm.
The Z-axis nut needs to be moved from above the platform to below it, or the z-axis won't have enough travel. Custom Replicator case increases build height by 100mm.
The cut files on Thingiverse for the Replicator case ( www.thingiverse.com/thing:18813 ) are NOT right, and not the files used for production. The Mightyboard has moved, so I needed to 'edit' my case with a dremel.
Bottom view of the heater block mounted to the heat spreader bar and XY plate. Note that the heater block has been put on at an odd angle owing to the large head of the M6 bolt. Consider using a M6 bolt with a smaller head such as a socket cap head.
Assembled extruder with heatsink and 24 VDC fan, front view.
Be sure to use a 40 x 40mm 24 VDC fan. MBI uses approximately a 5 CFM fan, but you can get much better, quieter fans which move more air (higher CFM). The fan shown is approximately 7 CFM. Note arrows molded into the side of the fan and orient the fan such that it blows towards the heatsink.