This mod enables the mounting of a stepper motor and extruder directly to the x/y carraige of the Two Trees Sapphire S CoreXY printer, plus the brackets for an E3D V6 Hotend. The mod includes a remix of thing 3396264 by 2bedom, which is itself a remix of the MK3 R3 mounts.
This mod also includes components from :
https://www.thingiverse.com/thing:3249344 - Mk3 Nozzle by RH_Dreambox
https://www.thingiverse.com/thing:2758290 - BL Touch Mount by m3lvm
Features and changes include :
Enables stepper and extruder to be mounted directly above V6 hot end, to eliminate the poorly implemented original extruder/bowden configuration. Technically there still is a little bit of visible bowden between the extruder and hotend, but this is necessary to accommodate the frame.
Adds 20mm+ to the available Z build height by raising the hot end mount position, all other build dimensions remain the same.
Replacement of 5015 50mm fan with a 4020 40mm fan for part cooling - This fixes the issue of the 5015 fan colliding with the front right axis rod at the extreme of its travel.
Added cable support to extruder mount, to better support main wiring harness (requires zip tie)
Added V2 of the extruder mounting bracket, which has improved strength and new cable management features to allow all cables (excluding thermistor and hot end power) to be constrained above the xy carriage rail, which reduces the possibility of any cables rubbing on the z axis screw.
I have modified the nozzle to accept a vertical 5015 set 90 degrees to the v6 mount, this allows a 5015 fan to be used without compromising the build volume on the X axis. This change also includes a new fan support bracket. Using a 5015 fan delivers better part cooling air flow. (I will be the first to admit its not visually appealing, but it is functional and an improvement over the 4020 fan solution)
I printed everything in ABS to avoid any thermal warping issues, the extruder bracket, fan arm, and fan adaptor could be printed in PETG if desired.
Printed V2 of extruder mounting bracket in PETG @0.3 with 4 perimeters and 25% gyroid infil.
You may need to increase the size of the fan adaptor by 1% or 2% depending on your print tolerances, its designed to be a tight fit over the original nozzle.
1 x 4020 40mm Radial Fan - (You can use a 5015 50mm Fan and standard R3 fan mounts but you technically loose a little print volume of around 5mm on the x axis)
1 x 40 x 10mm Fan for hotend cooling
1 x BL Touch (optional) (Don't forget to adjust z-endstop switch if not replacing with BLTouch)
The standard square nuts, hex nuts, and bolts that are required for the Original MK3 R3 mount plus:
1 x M3 x 16mm - for fan arm
1 x M3 x 20mm - for attaching fan to arm
1 x M3 x 10mm - for BLTouch mount
4 x M3 x 10mm - for mounting extruder bracket to x/y carriage/rail
2 x M3 x 10mm - for mounting rear V6 mount to extruder bracket
2 x Zip Ties - for securing wiring harness
1 x Stepper Motor extension cable
You will also need the 2 original M4 bolts used to attach the original hotend to the x/y carriage, for attaching the rear v6 mount.
If using a BMG extruder:
3 x M3 x 40mm - to mount extruder and stepper
1 x 65mm Bowden Tube
This is functional but still a work in progress...
The alignment of my extruder (bmg clone) and hotend is slightly off-centre, this is to ensure that the mass of the extruder and stepper motor remain centred on the x/y carriage - it may be different if using a different type of extruder. I do not think this is an issue, but I may try and fix this in a later version.
I want to add more strength to the extruder mounting bracket - I originally intended it to be used with a pancake stepper motor, but it got too hot for my liking - so I reverted back to a standard size, and I have noticed a little flexing of the mount now. However this may be solved by using PETG instead of ABS......
Update 04/06/2019 : V2 of extruder mounting bracket has improved strength and new cable management features - I will leave V1 for anyone who wants to run with a pancake stepper and wants an alternative lighter weight version.
It may be prudent to allow some reduction in jerk values in your config/slicer settings when printing at high speed, due to the added weight on the x/y carriage. I have not noticed any issues so far, but I am monitoring.
Mount extruder bracket and run stepper motor cable through wiring harness
Attaching rear V6 mount
Insert and align V6 Hot end
Attach V6 Front, HE Fan, Fan Arm, nozzle, Fan Adaptor, and Cooling Fan
Attach BLTouch (don't forget to calibrate the height once build is complete!)
Insert the bowden into the V6 Hotend, attach the extruder and stepper to mounting bracket
Arrange cables above x/y carriage rail, and zip tie harness at the bottom and top
Test Prints with Vertical 5015 fan. Left = PETG. Right = PLA. Both @ 0.2 layer height
Print times PETG = 1h39m PLA = 1h46m