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« Last post by ddmckee54 on August 16, 2025, 11:05:34 AM »
I've had a couple of set-backs in this project, and MOST of them are related to the M3 heat-set inserts that are SUPPOSED to hold things together.
Set-back #1 -
I recently installed the inserts into the upper and lower frame parts, I was trying to make the go roundy-roundy bits do exactly that. As I was installing them I noticed that they were going in rather easily. After I got all 2 dozen of them installed and started bolting things together, and MOST of the inserts failed when I tightened the bolts, I went looking for the culprit. Turned out I was the guilty party.
The frame parts were the first one designed, before I found and fixed the X-Y dimensional accuracy problem. Prior to fixing that problem my heat-set insert pockets would print under-sized, my solution was just to make them over-sized in the CAD model. Soooo... after I fixed the X-Y problem, my over-sized heat-insert pockets ALL printed over-sized.
Set-back #2 -
I Could try gluing the inserts in, but MOST of them are going to be under enough stress from the rotating upper frame that I'm not comfortable doing that. I don't think I've got enough filament left on the spool to re-print all the grey parts, and I couldn't find a manufacturer's label on the spool, so I just had to order some and hope for the best. The colors DON'T match. So I'm going to have to re-print most, if not ALL, of the visible grey parts.
Set-back #3 -
The grey filament that I was using was several years old, this made it stiff and brittle. If the printer sat unused for several days the stresses caused by just unwinding it would eventually cause it to break. I was working on the filler block that I need to install in the main drive gearmotors, before I clip the front corners off the gearmotor cases. When I tried to print them out, I got a print failure. Because the printer had been sitting unused for several days, the filament had snapped in the feed tube and I didn't catch it. The extruder was running empty for several minutes before I caught the problem. This running empty over-cooked the filament that was left in the extruder which caused a nozzle jam. No problem, fixed that easily. However, it also damaged the PTFE heat break liner, my LAST liner. I ordered some new spare liners, and some more 0.4mm nozzles - just to be on the safe side. They arrived, and rather than waste the remaining grey filament, I'm using it to print brackets to hold the OXA tool-holders for my Sherline lathe. Those brackets, and the gearmotor case filler blocks, finished printing last night. Now I'll pitch the remainder of the old roll of grey filament, switch to the new roll, and start re-printing the grey parts.
Don