Assembling the new hot end – Sumpod

Conrad Electronic UK
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EDIT 21/01/2012....It works a treat!!!

The method I used to assemble the new upgraded hot end was as follows

1.   The most important point to remember is that the PTFE tubing goes right to the end of the nozzle. To that end I measured the depth of the nozzle supplied and found it to be 11.78mm. Also it pays to chamfer the end of the tubing so it mates with the inside of the nozzle.

2.  The tubing, by its very nature, is slippery so I used some masking tape to provide grip. You need this as its a very tight fit, as it needs to be. edit 21 01 2012 measure mine with micrometer and it came in at 4.54mm!

3.   Because the top fitting has a one way mechanism it has to be placed close to its final position. A mark is made to show the length of tubing when it will be at the nozzle end (see photo) then the square stainless steel holder is pushed (with some effort) until just enough tubing protrudes from the end.

4.  The nozzle is then pushed (again with effort) onto the tubing and then secured by grub screw.

5.  The top fitting is then screwed down into place, completing this phase of assembly.

6.  The power resistor is placed into the hole into the square heater block. I held mine in place with fire cement (bought from any hardware/builders supplier) baked in an oven (at 200 deg C) to set it off.

7.  The heater block is then secured to the end of the nozzle with the grub screw. It must be as near to the tip as possible to heat the very end of the filament.

8.  The thermistor was then taped with Kapton tape on both very fine wire legs to keep them insulated and apart from each other. Once each leg is done then a piece of Kapton tape is put over both to keep the apart. Once done, the thermistor was secure near the tip (see photo) of the hot end with Kapton.

9.  I soldered both the Thermistor and the power Resistor leads rather than use the small crimps supplied.  Whilst very tiny, the thermistor wire soldered easily enough, then both sets of wires were insulated with heat shrink tubing.

10 Finally the hot end was screwed onto the heat sink, the fan was then secured in place and all put onto the MDF holder.