So it's been about a week and half since my last post...
I'll post a more detailed update in my Killing Time thread tomorrow.
I wasn't happy with the look of the parts in the translucent green PET, so I reprinted them in the eSun purple PETG.
Much better. I also printed all of the extruder upgrade parts with the included Prusa black PET since I wasn't sure which parts were critical to the functionality of the IR filament sensor.
Thursday I started tearing down my MK2 to upgrade it to the MK2.5S. I discovered that all of my linear bearings were bone dry. So I ended up tearing down all of the axis, pulling the bearings, cleaning them, and greasing them. I also cleaned and polished the linear rods.
That was more work than I had planned on, but I'm glad I spent the time to do it.
I ran into small issues along the way during the upgrade. The most annoying one was that the new MK52 heatbed required that my Y axis connector on the belt be rotated 180deg. instead of messing with that, I just pulled the whole bed carriage assembly and rails out, then rotated it 180 degrees. That way I didn't have to mess with my belt tension, which was perfect.
One unique one that I didn't discover until Thursday night was that my upgrade kit was missing the IR sensor PCB. I email Prusa right away that night since it was close to 6am Friday local Czech Republic time. They replied right away that a sensor board was being shipped to me and I had DHL tracking info by the time I woke up at 6:30am local Friday morning. They also told me how to disable the sensor in the new firmware once I had everything completed with the assembly, so I could start calibrating and printing this past weekend. I received my sensor this afternoon. I had already routed the wire and had everything in place for it, so it was super easy to install it.
Earlier I didn't think the genuine Prusa upgrade was worth it, but now that I have it all installed, I'm glad I bought the kit. I'm still planning to continue to upgrade the printer, but the money was well spent to get the new Bondtech extruder, new MK52 design 12V heatbed, and the removable steel spring build plates.
I have a lot of pictures of the process, but I'll spare you guys the pic puke unless you want to see more specific areas later...
Here it as it sits right now. And one minor, easy thing I did which made a huge aesthetic upgrade was peel off the ugly, yellow warning label.
And my first print on the upgraded printer was a new purple case for the Raspberry Pi 3B for Octoprint. The RSP 3b came with the printer, but I never used it. Now i'm going to use it, so it needed a proper case.
And installed I discovered that it mounts "upside down", so I spent some time on Thingiverse last night tracking down the STLs for my original black case and found them! Tomorrow or Wednesday I print a purple version of the original case.
I also downloaded some other parts to add or upgrade the printer that I need to print. I have all the G-codes exported so I just need to fire it up tomorrow in the morning and get it going. After those parts are done, I will be going back and reprinting a lot of the stock black parts in the new purple. Mostly for looks, but I did discover that a lot of the parts on my printer are getting a little brittle or they just were not printed very well to begin with. Apparently this is not uncommon with the MK2 Prusa kits. They were so backlogged they didn't print for aesthetics, just functional parts. I will be reprinting for improved strength and improved aesthetic finish...
Because my printer sits on a cart in the basement under our bedroom, I'm not allowed to run the printer over night. I need to build an noise abatement enclosure to put around the printer on the cart so I can run it 24/7 if I need to. I'm going to use acoustic ceiling tiles for the inside since they abate noise, they are white & diffuse light, and most importantly; they are fire rated to prevent or slow the spread of a fire in a structure. I already have a smoke detector on our basement wall right above the printer, but having a fire rated material on the inside and within the "walls/top" of my enclosure framework is just an extra bonus. And I will be putting it on the top of my cart under the printer and a couple layers on the underside of the wood of the cart. Again, the main reason being noise abatement, but every little bit helps.
The cart is perfect for the printer and my wife gave it to me when she decided she didn't want it in the kitchen anymore. I'm going to upgrade the casters to leveling casters and buy a roll of MLV to wrap around the base (going to use magnets to hold it on to the steel frame) to hide the spools and tools on the shelves, plus it will add weight to cart and help reduce vibrations. The MK2/MK2.5S will never be silent because of the drivers, but at least these mods to the cart and an enclosure for the top will help a lot.
I think the next phase of upgrades will be to source a green Bear Tall FULL upgrade frame and the taller Z axis motors with integrated screws.
I waffled on going with purple or orange, or even just plain black, but the more I see the green frames "in the wild", the more I like the green.
I'm about to order a black Dragon hotend from BIQU. I'll probably order the SKR V1.4 Pro control board at the same time, but that upgrade will be done in another phase. Final phase will be converting to 24V PS and 10mm linear rods on the Y and Z axis with all new Misumi Linear rods and bearings.
Of course, all of these upgrade phases require the printing of new parts, so that's the main reason I'm doing them in phases. I want to sprinkle in fun prints or more useful prints in between the printer upgrade partss. Plus I want to make sure I get any issues or bugs resolved with each phase instead of possibly having everything change at once with major issues I can't track down a root cause for.
Oh, I'm also seriously considering an Anycubic Photon resin printer and their Wash & Cure station, but I'm just not sure I want to mess with the resins and disposal of the wash IPA contaminated with resin. The quality and speed of the high detail prints is pretty tough to ignore though.
Cheers -
