Project Dashboard LulzBot Mini 2 Bed Plate Assembly Workflow

1 Gather materials

Gather the required materials:
1x- [PP-FP0138] Silk Screened Bed Mount Plate, Mini
1x- [AS-PR0060] belt-mount black v1.2 Assembly
1x- [PP-GP0277] belt-clamp black v1.2
1x- [PP-IS0073] Mini 2 Single Bearing Holder with Inserts
1x- [PP-IS0066] Mini 2 Double Bearing Holder Non-Switch Side Insert Assembly
1x- [PP-IS0064] Mini, Y Axis Rod Mount, Motor Side
2x- [PP-GP0332] Bump Stop
4x- [PP-GP0477] Flexy Bed Corner v2.2.4
3x- [HD-NT0001] Metric Zinc-Plated Steel Nylon-Insert Locknut
4x-[HD-BT0039] Metric Class 12.9 Socket Head Cap Screw
2x- [HD-RD0035] 8mm Smooth rod, 315mm, 300 Series Stainless Steel
4x- [HD-BT0107] Metric Class 12.9 Socket Head Cap Screw Alloy Steel, Black, M2 Thread, 10mm Length, 0.4mm Pitch
4x- [HD-WA0012] Steel Flat Washer, DIN 125 zinc-plated class 4,M2 screw sz, 5mm OD, .25mm-.35mm thick
17x- [HD-BT0137] M3 x 8 Bolt, BHCS, Black-Oxide
21x- [HD-WA0038] Black-Oxide 18-8 Steel Flat Washer, M3 Screw Size, 3.2mm ID, 7.0mm OD
6x- [HD-BT0128] M3 x 6 Bolt, FHCS Black-Oxide
1x- [HD-BT0104] M3 x 8 Bolt, BHCS, SST
1x- [PP-GP0264] y-idler-mini_black_v1.4 (with 4x- M3 Inserts [HD-MS0030] already installed)
1x- [HD-BT0117] Black Alloy Steel Flat-Head Socket Cap Screw, M8 Size, 40mm Length
2x- [HD-MS0282] 608-2RS ABEC3/C3 Rubber Sealed Bearing - BLACK
1x- [HD-NT0002] M8 Nyloc Nut, Zinc Plated
3x- [HD-WA0006] M8 Washer, Steel, Zinc Plated
1x- Bed Plate Jig
1x- [AS-PR0104] Double Bearing Holder Assembly, Mini 2
1x- [AS-PR0113] Single Bearing Holder Assembly, Mini 2 1x- [AS-CB0071] Mini 2 Bed Harness

Materials Required
Materials Required

2 Install jam nuts

Put the M3 nyloc nut [HD-NT0001] into the 5.5 mm nut driver that has been ground down to 7.5mm in order to fit inside the Y-Rod Mount.
Insert the 5.5mm nut driver into the longer hold of the Y-Rod Mount. Make sure you press the driver to the bottom of the bore. Then, use a M3 x 12 SHCS [HD-BT0039] and an M3 washer [HD-WA0038] to pull the nyloc into the hexagon shaped hole in the printed Y-Rod Mount [PP-IS0064] with a 2.5 mm hex driver or electric screwdriver.
Inspect the nyloc nut to make sure it is seated into the nut trap correctly.
Back the screw out until it is flush with the printed part.
Repeat this process for the other side of the printed part.

Required materials
Orientation of nyloc nut
Nyloc nut ready for insertion
Nyloc nut ready to be pulled into nut trap
2.5 mm driver pulling nyloc nut into nut trap
Screw backed out until it's flush
Inspect the nut
Repeat on other side
Pulling the nut into the nut trap
Screw flush with printed part
Inspect the nut

3 Assemble Y Idler

Materials Required to complete AS-PR0069:
1x- [PP-GP0264] y-idler-mini_black_v1.4 (with 4x- M3 Inserts [HD-MS0030] already installed)
1x- [HD-BT0117] Black Alloy Steel Flat-Head Socket Cap Screw, M8 Size, 40mm Length
2x- [HD-MS0282] 608-2RS ABEC3/C3 Rubber Sealed Bearing - BLACK
1x- [HD-NT0002] M8 Nyloc Nut, Zinc Plated
3x- [HD-WA0006] M8 Washer, Steel, Zinc Plated

Drop two 608zz bearings [HD-MS0282] sandwiched between two M8 washers [HD-WA0006] into the recess in the printed part as shown.
Put a M8 x 40 mm FHCS [HD-BT0117] through the countersunk hole in the printed Y-Idler part [PP-GP0264].
Place an M8 Washer [HD-WA0006] and an M8 Nyloc Nut [HD-NT0001] on the end of the M8x40 Bolt.
Use a 5mm driver and a 13mm wrench to turn the nut onto the bolt.
Turn the bolt until the nut touches the washer and prevents up and down motion of the bolt in the printed part, but Do not tighten it.

Materials
Hardware order
Tightening
Complete

4 Install bed corners

Using M3 x 10 BHCS [HD-BT0137] and M3 washers [HD-WA0038] fasten the urethane bed corners [PP-GP0477] to the bed plate [PP-FP0138] with a 2 mm hex driver. These may be left loose for the time being; they will be tightened in position with the bed heater at Calibration.

Materials
Fastening

5 Install ground screw

Install the M3 x 8 stainless steel BHCS [HD-BT0104] into the threaded hole towards the bottom left of the bed plate as pictured.

Location of grounding screw

6 Install belt clamp

Attach the belt clamp [PP-GP0277] to the belt clamp assembly [AS-PR0060] using two M3 x 12 SHCS [HD-BT0039] and two M3 washers [HD-WA0038] with the wider side towards the base of the mount. Leave the screws loose as they will be tightened at the Final Mechanical Assmebly.

Materials
Belt clamp assembly

7 Install bumpers

Using M2 x 10 SHCS [HD-BT0107] and M2 washers [HD-WA0012] fasten the urethane bumpers [PP-GP0332] to the single bearing assembly [AS-PR0113] with a 1.5 mm hex driver.

From behind the bushing assemblies are identical. Make sure to use the single bearing holder shown on the right
Materials
Fastening

8 Install bushings and belt clamp

Use the printed bed plate jig to install the bushing holders and belt clamp.
With the ground side closest to you, place the single bushing holder [PP-GP0134] on the left side.
The bump stops should fit into the indents of the jig.
Then place the double bushing holder [PP-GP0133] on the right side with the cutouts facing the center of the jig.
Place the belt clamp assembly in the center with the flat edge and screws to the left.
Set the bed mount plate on top with the ground screw in the bottom left corner.
Secure the double bushing holder, belt clamp, and the right half of the single bushing holder with 9x M3 x 8 bolts[HD-BT0137] and 9x M3 washers[HD-WA0038].
Leave these screws loose as they will be tightened at calibration. Secure the left half of the single bushing holder with 2x M3x 6 bolts[HD-BT0128].

Jig used
Parts placed in jig
Tightening
Screws installed

9 Install smooth rods

Use the 8 mm reamer tool [TL-PW0225] to gently ream the y idler assembly [AS-PR0069]. Take care to keep the tool straight and to not remove too much material which would result in a loose fitting rod. Take note of the orientation of the bushing holders shown in the picture, then slide the smooth rods into the bushing holder assemblies. Seat the rods in the y idler assembly. If the rods do not seat, it might be a sign that the reamer tool needs to be used to clean up the diameter of the blind hole in the printed part. Slide the other end of the rods into the motor side mount [PP-IS0064].

Materials
Hand-reaming
Assembled
beep

10 Install wire harness

Using two [HD-BT0128]* screws and one locknut [HD-NT0001] attach the mini 2 bed harness **[AS-CB0071] to the bed plate assembly. Tighten the screws through the holes in the mounting brackets in the harness. Place the brown and white grounding wires around the grounding screw and tighten with the locknut. Insert the brown and pink wires into one bump stop and the green and gray wires into another as shown in the picture.

Screw installation
Wire and locknut placement
Tightening
Wires in bump stops

11 Check your work

Make sure what you have looks like the picture.

Finished assembly
Done! Take me home