This is my newly designed and built Makerbot Replicator Enclosure that does not require a laser cutter to make. It can be built using your Makerbot Replicator, a band saw, drill press, and one screw driver for assembly. It uses 1/4 inch thick acrylic plastic for all the clear parts so that it will not sag because it is to light weight for the sizes that are needed. It cost less than half of what it would be to have the parts laser cut for you. The top hood and front window opening are easily removed in seconds without tools so it is simple to access the Makerbot when you want to make adjustments, print a part or remove finished parts.
The first step in creating the enclosure is to cut out all of the clear acrylic plastic parts using a band saw and a drill press. The only part that is a little complicated to make is the front window. In the top center of the part is a 1/4 inch radius shown on the drawing for the part. To make this radius first drill a 1/2 inch hole and then mark the rest of the profile per the drawing provided. Do not remove any of the plastic film that is normally on acrylic plastic panels. This protects the part while you are cutting, drilling or sanding edges. It also makes it easier to mark the part as a Sharpie pen works best and the marks will not remain on the part once it is completed when the plastic film is removed just before final assembly.
The complete assembly is put together using a variety of brackets printed on the Makerbot and held together using 10-32 x 1 inch machine bolts and nuts. Forty-two bolts and nuts are required for the assembly. All Makerbot parts have recessed areas for the nuts so no wrench is needed to put the assembly together. Just a screw driver is all you will need. Refer to the parts illustration as to the correct location of each part. The corner mounts #1 and #2 are bolted together first for each corner. The recessed nuts will sit just below the surface of the assembly so it will mount easily onto to the Makerbot Replicator
Take your time with the cutting and drilling as all holes are 1/4 inch which will allow tolerance to be built into the design to allow for correct fit when assembly is underway. All hood panels should sit flush with the top inner surface of the Makerbot so that holes will line up for the bolts to be installed. If the bottom edge of a panel does not sit flush then recut the notches that are in the panels on both ends to clear the mated printed Makerbot corner pieces. This will allow for better alignment of mounting holes in the assembly.
After all acrylic parts have been cut, sand edges smooth using sand paper being careful not to scuff the facing surfaces. The side windows for the Makerbot Replicator are drilled and cut to make the slots for assembly into the Makerbot. To hold these parts in place you will need to print out "Side Panel Clips" by Etrohn found here on Thingiverse. These are quick and easy to print on the Makerbot and easy to install in the assembly. If you should need more information and photos of this build please check out my blog site for more help. Thetinkersworkshop.blogspot.com