Project Dashboard LulzBot Bio Bio Bed Plate Assembly Workflow

1 Gather Materials

1x- [AS-CB0071] Mini 2, Bed Harness
4x- [HD-BT0039] M3x12 SHCS, Black-Oxide
1x- [HD-BT0104] M3x8 BHCS, SST
2x- [HD-BT0107] M2x10 SHCS, Black-Oxide
1x- [HD-BT0117] M8x40 FHCS, Black-Oxide
6x- [HD-BT0128] M3x6 FHCS, Black-Oxide
17x- [HD-BT0137] M3x8 BHCS, Black-Oxide
8x- [HD-BT0148] M3x10 BHCS, Black-Oxide
2x- [HD-MS0282] Rubber Sealed Bearing 608-2RS
3x- [HD-NT0001] M3 Locknut
1x- [HD-NT0002] M2 Locknut
2x- [HD-RD0078] Hardened Steel Linear Rod 315mm
3x- [HD-WA0006] M8 Washer
2x- [HD-WA0012] M2 Washer, Zinc
1x- [HD-WA0035] 18-8 External Serrated Lock Washer
29x- [HD-WA0038] M3 Washer, Black-Oxide
1x- [PP-FP0171] Mini Bed Mount Plate
1x- [PP-GP0133] Double Bearing Holder
1x- [PP-GP0134] Single Bearing Holder
1x- [PP-GP0249] Bed Clip
1x- [PP-GP0263] Y Motor Mount
1x- [PP-GP0264] Y Idler
1x- [PP-GP0277] Belt Clamp
1x- [PP-GP0278] Belt Mount
1x- [PP-GP0332] Bump Stop
4x- [PP-GP0396] Bed Corner
1x- [PP-MP0258] Bottom Plate Mini

Gather Materials
Gather Frame Pieces

2 Install Jam Nuts

Put the M3 locknut [HD-NT0001] into the 5.5 mm nut driver jig, the nylon ring on the locknut should be on the bottom.

Insert the nut driver into the longer hold of the Y-Rod Mount. Make sure to firmly press the nut driver inside the hole.

Then, use a M3x12 SHCS [HD-BT0039] and an M3 washer [HD-WA0038] to pull the nyloc into the hexagon shaped hole in the printed Y idler [PP-GP0263].

Inspect the locknut to make sure it is seated into the nut trap correctly.

Back the screw out until it is flush with the printed part, and then repeat this process for the other side of the printed part.

Materials
Place locknut in the nut driver jig
Align the nut driver with the longer hole on the Y motor mount
Inspect the head of the screw, make sure it's flush with the surface
Repeat for the other side

3 Assemble Y Idler

Place 2x bearings [HD-MS0282] inside the Y idler jig then set 2x M8 washers [HD-WA0006] next to the bearings.

Put a M8x40 FHCS [HD-BT0117] through the countersunk hole in the printed Y idler part [PP-GP0264]

Place an M8 washer [HD-WA0006] and an M8 locknut [HD-NT0002] on the end of the M8x40 FHCS. Use a 5mm driver and a 13mm wrench to turn the nut onto the bolt.

Fasten bolt until nut is tight against the washer and bearing can freely spin, but do not tighten it.

Prepare the Y idler jig with bearings and washers then place bolt
Place and washer and thread nut onto the tail of the bolt
Fasten the bolt to secure the idler, make sure bearing can freely spin
Set the assembly a side

4 Install Bumper

Using 2x M2x10 SHCS [HD-BT0107] with M2 washers [HD-WA0012] fasten 1x bump stop [PP-GP0332] to the single bearing holder [PP-GP0134]. The round side of the bump stop will hang over the side of the single bearing holder.

Fasten the bump stop to the single bearing holder

5 Assemble the Belt Clamp

Attach the belt clamp [PP-GP0277] to the belt mount [PP-GP0278] using 2x M3x12 SHCS [HD-BT0039] with 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 Assembly.

Make sure to install the belt clip with the treads on the inside to grip the belt

Materials
Attach the belt clamp to the belt mount (Correct orientation smooth side facing out)
Not acceptable (Belt Clamp is installed backwards)

6 Install Bed Corners

Using 2x M3x10 BHCS [HD-BT0137] and 2x M3 washers [HD-WA0038] fasten 1x flexy bed corner [PP-GP0396] to the bed plate [PP-FP0171].

Then repeat step for the other three bed corners.

These may be left loose for the time being; they will be tightened in position with the bed heater at Calibration.

Install the flexy bed corner
Repeat for the other three corners

7 Install Ground Screw

Install the M3x8 BHCS SST [HD-BT0104] into the threaded hole towards the bottom left of the bed plate as pictured.

Install a M3x8 stainless steel screw into the designated spot

8 Assemble the Bed Plate

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 left half of the single bushing holder with 2x M3x6 FHCS [HD-BT0128].

Then secure the left side of the single bushing holder, belt clamp, and the double bushing holder using 9x M3x8 bolts [HD-BT0137] with M3 washers [HD-WA0038].

Tighten the right side of the single bearing holder and the belt clamp, but leave the other screw loose.

Single bushing holder on the left and double bushing holder on the right
Parts placed in jig
Align the bed plate with the assemblies inside the jig
Attach the single bearing holder using 2x M3x6 FHCS and 2x HD-BT0137 w/ HD-WA0038
Repeat for the belt clamp and double bearing holder
Once all the assemblies are loosely attached to the bed plate tighten the designated screws

9 Install Harden Steel Rods

Use the 8 mm reamer to gently ream the Y idler. 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.

Slide 2x harden steel rods [HD-RD0078] into the double and single bearing holders.

Then take the Y idler and slide it on the end of the rods making sure its closest to the ground screw on the bed plate. If the rods do not seat, it might be a sign that the reamer tool needs to be used to clean up the hole in the printed part.

Now take the Y motor mount [PP-GP0263] and slide it on the other end of the rods.

Slide the steel rods into the single and double bearings
Use the 8mm reaming tool and ream the two holes on the Y idler
Slide the Y idler on the end of the two rods making sure its closest to the ground screw
Then slide the Y motor mount on the other end of the rods

10 Attach the Wire Harness to the Bed Plate

Using 2x M3x6 FHCS [HD-BT0128] attach the Mini 2 bed harness [AS-CB0071] to the bed plate. Use the end of the cable chain that has the wire connectors.

Place 1x M3 internal tooth lock washer [HD-WA0035] and the brown and white grounding wires around the grounding screw and tighten with 1x M3 locknut [HD-NT0001].

Attach the cable chain on the bed harness to the bed plate
Place a lock washer around the ground screw
Place the brown and white ground wires around the ground screw
Use a locknut to secure the ground wires to the ground screw

11 Attach the Bottom Frame

Align the cable chain mount with the two holes in the bottom plate [PP-MP0258] and secure using two M3x6 FHCS [HD-BT0128].

Flip the bed plate assembly so the bed plate is resting on the table, then carefully flip the bottom frame plate and bed plate into position as shown.

Using 4x M3x8 BHCS [HD-BT0137] with M3 washers [HD-WA0038] secure the Y axis idler to the bottom frame plate.
Make sure the front of the Idler printed part remains flush with the idler mount of the Frame.

Secure the Y motor mount to the motor mount flange of the bottom plate using 4x M3x8 BHCS [HD-BT0137] with M3 washers [HD-WA0038].
Make sure the back of the Y motor mount remains flush with the motor mount flange of the frame.

Finished bed plate assembly and bottom frame plate
Align and fasten the cable chain to the bottom frame plate
Flip the bed plate assembly so it's resting on the bottom frame plate
Holding the bed plate in place flip the bottom plate over
Secure the Y idler to the bottom frame plate
Secure the Y motor mount to the bottom frame plate

12 Tighten the Single and Double Bearing Holders

Flip the assembly over so the bed plate is on top, and tighten the two loose screw holding the single bearing holder.

Then slide the bed plate all the way towards the Y motor mount until it stops. Then tighten one of the screws holding the double bearing holder.

Now slide the bed plate the other way until it stops so that its covering the Y idler. Then tighten the screw that diagonal from the screw that was previously tightened.

Slide the bed plate assembly to the middle of the rods and tighten the other two screws.

Tighten the single bearing holder to the bed plate
Slide the bed plate so it covers the Y motor mount and tighten on of the screws holding the double bearing holder.
Then slide the bed plate to the other end of the rods and tighten the opposite screw
Now slide the bed plate to the middle of the rods and tighten the other two screws.
Make sure all the screws are tightened on the bed plate
Done! Take me home