Difficulty
Difficult
Steps
23
Time Required
- 3. XY axis base 23 steps
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Quiz
0
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We are using t-nuts to attach parts and plates to the extrusions. These t-nuts slide inside the extrusion.
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The Bear Upgrade 2.1 comes with custom designed t-nuts that can only be inserted in the correct orientation.
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If you use Openbuilds hardware or other kits your t-nuts need to be inserted in a certain orientation.
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Tech note: our new t-nuts reduce the chance of damaging the frame, have a longer and more precisely machined thread and being manufactured from stainless steel, they are rust free.
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Here are some tips on how to tighten screws; to avoid damage, to make alignment easier and to ensure consistently torqued screws.
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If you have several screws to tighten together, always tighten them incrementally until they are snug.
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When you have 3 screws you can follow this tightening sequence:
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Start with the middle one
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Continue to the second one
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Tighten the third one and repeat until all screws are snug.
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Take one of two longest extrusions. It is 370mm long.
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On the 20mm face of the extrusion, slide 2x t-nuts on each side (4x t-nuts in total).
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Bolt 2x joining plates on the t-nuts using 4x M5x10mm screws. Do not tighten them fully yet.
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Take your time with this step.
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Make sure that you are workng on a flat and level surface.
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Take a joining plate and hold it against the extrusion, as shown in the 1st image. We will use it to aid in the alignment of the first joining plate
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Hold the plates as shown in the 2nd image, applying pressure as shown (small green arrows) and fully tighten both M5 screws.
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Check that your plate is flush with the face and end of the extrusion.
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This is an important step as other steps will rely on the accuracy of this assembly.
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Take your time with this step.
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Repeat the instruction from Step 4, to align and attach the the joining plate at the other end of the extrusion..
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Check that this plate is also flush with the face and end of the extrusion.
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This is an important step as other steps will rely on the accuracy of this assembly.
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Take your time with this step.
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Take the longest extrusions. It is 370mm long.
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Repeat Step 3 and 4 on this extrusion. You should now have two identical assemblies.
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Double check that all your plates are correctly flushed with the extrusion.
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This is important as other steps will depends on this assembly.
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Take one the two middle length extrusions on the pile of unused. It is 331mm long.
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Prepare the following parts:
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1x previous extrusion and plate assembly
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2x t-nuts. Slide them in the 331mm extrusion as shown on the picture.
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2x M5x10 screws
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Assemble the corner with the M5 screws. Do not tighten fully yet!
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Take your time for this step, it will be a reference for the rest of the assembly. Ask the help of someone else if you feel the need of a third hand.
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Make sure you are on a flat and plane surface.
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Place the assembly vertically.
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Be careful to not let fall down the assembly.
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Square the extrusions with a square.
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Apply pressure in the directions shown and tighten strongly the two M5x10 screws.
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Tech tip: This step can be easier if you have a clamp. You can then secure the thicker side of your square to the vertical extrusion as shown in the 3rd image.
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Verify that the assembly is still square after tightening. Correct it if needed.
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Prepare the following parts:
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One t-nut.
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One M5x12 screw
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One 3D printed foot (foot.stl)
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Slide the t-nut from the right side.
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Tighten the foot with the M5x12 screw.
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The corner with the foot is now considered as a reference. In case of doubt during the next steps, you know that this corner is perfectly square and you don't have to touch it anymore.
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You can double check that the five M5 screws are all strongly tightened.
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Take the last middle length extrusions on the pile of unused. It is 331mm long.
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Prepare the following parts:
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2x M5x10 screws.
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2x t-nuts. Slide them in the 331mm extrusion as shown on the picture.
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Assemble the 331mm extrusion with the M5 screws. Do not tighten it fully yet!
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Take your time with this step.
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Take one the smallest extrusions on the pile of unused. It is 290mm long. It will be used for reference.
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Place the assembly at the end of a table.
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Carefully insert the 290mm extrusion in between as shown in the 2nd image.
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Be gentle or you might mark permanently the assembled extrusions.
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Apply pressure in the directions shown and tighten the 2x M5x10 screws strongly.
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Remove carefully the 290mm extrusion carefully and reserve it for later.
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Take 16x t-nuts and test them individually with an M5 screw.
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Those 16 t-nuts will require to disassemble the base of the frame in case one is defective. It is then better to verify them first. You can thanks 3DMN for this handy tip :)
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Double check you have used the correct extrusion lengths:
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370mm
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331mm
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Take 12 of the previously tested t-nuts. They will be inserted on both 20mm sides of the extrusions.
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Inserts 3x t-nuts on each side (12x in total) as seen on the 2nd and 3rd picture.
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Flip the assembly. Be careful to not loose any t-nuts!
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Take the last 4 t-nuts you previously tested and slide them in the extrusions as shown on the image.
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Tech tip: you can tape the t-nuts with the center of the extrusions, this will avoid to loose them during the next steps.
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Do not place tape on the sides of the extrusions, only on the center. The sides will be used as a reference and the thickness of the tape could affect the quality of your squaring.
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Flip the assembly. Be careful to not loose any t-nuts!
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Take 4x t-nuts and slide them as seen on the 1st picture.
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Take the second 370mm extrusion + plate assembly you have build in step 5. Assemble it with 4x M5x10 screws. Do not tighten them fully yet!
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Verify you still have the 12x t-nuts inserted on the sides of the extrusions.
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Your assembly is now looking as the XY base of your future frame :)
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Take your time with this step. Ask the help of someone else if you feel the need of having a third hand (please don't use one of your foot :) ).
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Move the XY base in vertical position with the 3D printed foot on the bottom left.
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Be careful to not let fall down the XY base.
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Make sure you are on a flat and plane surface.
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Apply pressure in the directions shown and tighten strongly the 2x M5x10 screws.
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Take your time with this step. It is the last squaring operation for the XY base :).
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Move down the assembly with and position the 3D printed foot on the left and back.
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Carefully insert the 290mm extrusion in between as shown in the 1st image.
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Be gentle or you might mark permanently the extrusions.
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Apply pressure as shown in the image and tighten the M5 screw strongly.
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Verify that all the 6 latest M5x10 screws bolted are fully tightened.
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Prepare the following parts:
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3x 3D printed feet (foot.stl)
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3x M5x12 screws
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3x t-nuts
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Assemble the 3 feet using the M5x12 screws and t-nuts.
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Flip the assembly (yes again!).
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Prepare the following parts:
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4x angle corners
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4x t-nuts
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8x M5x8mm screws
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Remove the tape of the 4 t-nuts and slide them close to the vertical extrusions.
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Insert t-nuts on the vertical extrusions.
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Assemble an angle corner with 2x M5x8 screws to each corners. Do not tighten them fully yet!
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For each corners, tighten alternatively the two M5x8 screws while applying pressure as shown on the images.
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The angle corners might twist a little the frame during tightening, we will solve this in the next step. Applying pressure while tightening reduce this.
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Tech note: this is why the Bear frame is not using angle corners in another place.
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Make sure you are on a flat and plane surface
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Check that the frame is not twisted by pressing on each corners one by one.
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If the frame remains flat you can continue to the next step.
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If the frame is wobbling, place a 5-10mm thick object under the opposite corner as shown in the 2nd image.
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The little up-down green arrow shows the wobbly diagonal. It might be the other diagonal for you, in this case, place the object in the bottom right corner.
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Apply pressure on the wobbly corners on both sides at the same time. No need to apply strong pressure.
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Now remove the thick object and verify again that the frame remains flat. If it is still wobbling, repeat those steps until it remains flat.
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If this is still not working double check if your surface is flat. If this is the case then unscrew a little the angle corners and repeat previous step and then current one.
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Congratulations you have finished the hardest part of the assembly :-)
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Got to the next chapter: 04. Z axis frame
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