5. Wire Harness

X assembly and Extruder

Bags with wires

4" zip ties and 6" zip ties

M2x16 bolts (2)

M2 regular nuts (2)

M2 regular washers (2)

Long Spiral Wrap and Short Spiral Wrap

Pre-install a 4" zip tie with a head out on the right side of the X carriage.

Note: this is a common procedure. Why else have a quick release extruder?

Loosen the quick release clamp and insert the extruder. The pink diamond shaped face will slot into the green grooves on the front of the X-carriage.

Make sure the HotEnd wires pass under the X carriage and especially under the fan wires.

Tighten the quick release clamp to hold the extruder in place.

Form two 5" zip tie loops.

Place the loops on the two stand-offs with the tails pointing and bending towards the HotEnd. (Tooth side facing towards the bottom of the assembly.)

Snip off about 1'' from each zip tie (2.5cm)

Then, thread one 4" zip tie inside each 5" loop.

Really, just watch the videofor this part. It's a better learning experience; the images can't easily convey how the wire slack should feel and what are the wire paths.

If you insist, here's some text:

Attach the hot end wire.

Leave the proximity sensor disconnected for now.

Connect the two fan wires.

The left fan connects to the end of the wire.

The other connector attaches to the right fan.

Use the zip tie in the side of the carriage to hold the wires in place.

After tightening the tie, snip off the end.

Connect the heat block and thermistor wire.

Connect the wire for the extruder motor to the header on top of the motor.

Connect the proximity sensor to the wire you left hanging earlier.

Use the 4" zip tie on the spacer to hold the wires. Keep it loose so you can adjust the wires. Make sure all the wires have enough slack and are not being pulled.

When you're happy with how the wires sit, tighten the zip tie and snip the end.

Attach the X motor wire to the header on top of the motor.

Above the X motor is a hole in the frame. Thread the x motor wire through it.

Use a 4" zip tie to secure the X motor wire. Make sure there's plenty of slack in the wire. This will result in a cute wave as the X motor wire goes up first and then curls down.

Place two M2 washers onto two M2x16 bolts.

Use the bolts and two M2 nuts to secure the end stop in place.

Use the 4" zip tie attached earlier to form a loose loop around the wires. All the wires must enter the loop from the same direction (from the right in the picture); including the X end stop and X motor wires.

Adjust the cables so they form a gentle curve with plenty of slack. Slack Slack Slack. Don't leave wires hanging, but they need their space.

Tighten the zip tie and snip off the tail.

Make sure the X carriage is at the end of its run.

Make sure none of the connections are being pulled on.

Use two more 4" zip ties to bring the tails of the two 6" ties into the bundle.

Use the shorter piece of spiral wrap to cover the wire bundle. Leave the spiral wrap loose so it can fold smoothly.

Snip off any excess length.

Use the longer piece of spiral wrap on the rest of the wires. If you're building with a friend this is a good place for a race to see who can wrap the remainder faster.