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Edge view of the XY plate, heat spreader bar, and heater block with nozzle.
If you have some heatsink grease, use a small amount of it on the nuts. Apply a very thin layer of it to the nut faces which face the heat spreader bar as well as to their threads. That will further help transfer heat from the thermal barrier tube to the heat spreader bar.
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.
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.
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.
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.