Flat Mesh Top Hat for 350mm Voron 2.4

This top hat mod for a Voron 2.4 350mm adds 117mm to the height of the Voron, which is great for using an umbilical instead of the standard cable chain. It also allows for moving a screen to the top, along with the Pi., there's also a mount for a fan to cool the Pi and screen. If a screen isn't desired in the top hat, it can be made with one of the middle side panels up front instead. The side middle pieces, corners, and top clips will need to be printed with supports. There is a second version of the TFT backplate that has a mount for a couple WAGO 221-413 connectors and mount for the USB board for the Nitehawk-36 USB Adapter PCB.

BOM:

• (62) M3 heat set inserts (need 8 less if not using the screen mount)
• (20) M3 - 6mm SHCS (socket head cap screw) to connect the top clips to the panels
• (32) M3 - 8mm SHCS to connect the panels together
• (24) M3 - 10mm SHCS to connect the panels to the T-Nuts (if using the screen mount you'll need extra 14mm screws where the clips will go)
• (4) M3 - 12mm SHCS to attach the screen cover to the backplate (only needed if using the screen mount)
• (4) M3 - 14mm SHCS to mount the fan into the screen housing (only needed if using the screen mount)
• (24) M3 Hammerhead T-Nuts to attach to the 2020 extrusion
• (4) M2.5 x 16mm SHCS to attach the TFT70 to the backplate.
• (1) 3010 fan (only needed for the screen mount)
• (8) 128mm x 104mm x 3mm thick plexiglass for the corner panels
• (2) 167mm x 104mm x 3mm thick plexiglass for the middle pieces (add one more if using one for the front instead of the screen mount)
• (2) rubber grommets for 1" holes (only needed if using the screen mount)

Each corner piece needs 6 heat set inserts, the A & B panels need 3 each, the middle panels need 1 each, the exhaust port panel needs 3, and the TFT section needs 9. Install all the heat set inserts first.

Then the plexiglass panels need to be installed. I found them to be a press fit when I installed them, but if they end up loose, you can carefully caulk a bit of silicone around the inside.

Install the hammerhead T-Nuts next. If using the screen mount, there are clips to run wiring around to the backside of the Voron. Decide where you want to mount these clips, and use 14mm screws instead of the 12mm to install them.

Attach all the panels together using the 8mm screws.

Mount the assembled top hat on the top 2020 extrusion, tighten up all screws.

If using, install the grommets into the TFT mount now, then run your wiring through the cable clips and through a preferred grommet. Mount the fan, then attach your Pi to the backside of the screen and wire it up as normal, including wiring the fan to the Pi. Insert the Screen into the holes that align with the mounting pins, then using the M2.5 screws secure the screen. The cover plate can now be mounted with the 12mm screws.

The standard plexiglass top piece fits on the top, use the standard single sided foam tape first, then place the plexiglass. Secure it all with the multiple panel clips and the 6mm screws.

Congratulations! Your top hat is done.