Uploaded two new versions of the .stl file:
- Should be the same as the original, but only contains a single object (some slicers have issues with multiple objects in a singe .stl file).
- Without "manual" support structure; it must be sliced/printed with support turned on. I wasn't real happy with the support that Slic3r generated for it; particularly under the large horizontal overhang; I think it should have printed support under the entire surface, but it only supported the edge, and gap-filled to make the surface...
After using my "version 2" fan holder (http://www.thingiverse.com/thing:216229) for a while, I had two problems with it. First, it totally obstructed the view of the print head, making it difficult to monitor the first layer of a print. Second, the nozzle was a bit too small; it was so close to the extruder, that it deformed slightly from the heat.
I had actually gone back to using my first cowling (http://www.thingiverse.com/thing:213416) with the second version's mounting parts.
This 60mm x 60mm x 10mm fan holder/cowling is designed to replace the left side-piece of the X carriage (see pictures). This fan holder and cowling has that part integrated into the design.
It has no adjustments for position (that should really be a fixed location, dictated by the carriage and extruder), and holds the fan more rigidly than my previous designs.
There is not much clearance between the fan/cowling and the left-side X motor mount. Make sure the screw heads are facing the front, and the nuts are in back. If they're the other way around, the fan will hit the screw tips when the X carriage gets near the left edge of the print area before reaching the edge of the print area. (see photos)
When the screws in the X motor mount are oriented with the nuts in back, it will be close, but it will clear, and the X carriage will be able to move all the way to the left until it hits the X motor mount/Z rod holder.
Print without support. The support required for the large horizontal overhang is part of the design, and is easily removed from the completed print.
Remove the left side-piece from the X carriage, and replace it with this part, using the original nut and screw.
Then attach the fan.
The tip may appear to be a bit too far forward; that's intentional because the airflow tends to be towards the back, even though the opening is parallel to the X axis due to the shape of the cone.