5KG / Dual 1KG Spool Holder

Prerequisites

What you need

• M3 Heated Inserts

  • (If enough demand for a version without heated inserts arise I might create a version with self tapping screws instead, let me know)

• Glue for rollers

• Clamps

• M3x15 screws + washers

• 8x22x7 mm bearings

Good to know

The spool rollers can be printed in two versions:

• A self aligning one.  Confirmed compatibility with Bambu Labs & Sunlu Spools:

  • 1x1KG

  • 2x1KG

  • 5KG

• A smooth cylindrical one.

I found that one of each works best, but if you have a spool of a different brand that doesn't align well with the self aligning one, then you might want to opt for 2 smooth ones.

You might want to start with the third build plate called Tolerance Test to ensure your printer is calibrated properly for the different snap fits. Go through the Assembly Instruction once to understand where every piece in belongs. 

Assembly Instructions

Installing the heated inserts

Long Frame Body: Topside (OPTIONAL)

There are 4 on the long frame body part. There will be used to screw down a top-cap to prevent the rollers from sliding.  If you plan to use the widest setting you may opt out of this one

L-Bracket Threads:

If you want to install the spool holder in a dry box or just want to ensure the components stick together        at all times and add some extra rigidity; the L-brackets must be installed. On all body panels you have          two tear dropped holes on its side. 

Assemble the body

1. Slide the Short Frame Bodies body over the long ones. It should be a tight fit, but shouldn't require too much force. Ensure you push them all the way down.

1. Lock the frames in place with the body bolts. These should also be snug, but shouldn't require brute force. If they don't slide all the way in you might not have pushed the frame bodies all the way down.

If the bolt is sliding out without any force you might want to scale them up in the xy-axis. However if you install the L-brackets they aren't really needed, but they do help keeping the frame in place for proper alignment. 

1. Install the feet by turning the entire frame upside down and screw in the long threaded screws. You may need to give them an initial push for them to start griping onto the inner thread. NOTE that if they are too tight, stop, print another set but scale them down slightly in xy-axis. Don't risk snapping them inside the frame. You could also use a normal M8 screw if you so desire.

The bolts can be fine tuned from above with a 3.5 hex bit. 

Prepare the Spur Gear.

Insert the the axle into the Spur Gear

Installing The Spur Racks (Roller Caddies)

Each housing pair for the bearings have a dove tail cutout in the bottom and the other at the top. They should be paired with one spur rack that has the dovetails on the left, and the other on the right. Like this:

Plant one of the spur racks at an angle like this to easily insert the spur gear axle into the hole. 

Place the spur rack flat now and move it all the way back.

Now do the same with the other half, placing it all the way in the back to align both sides.

Insert the adjustment knob from the outside of the frame.

Lock the spur racks in place by tightening the cap with m3 screws. NOTE if you over tighten the screws, you won't be able to turn the spur gear.

The opposite applies if you have the caddies aligned toward the middle. Not tightening the cap enough will cause them to slide if you put on enough weight on the rollers. 

Repeat the process on the other side.

Install the L-brackets

Use an m3 washer + screw, ensure the flat part of L-bracket aligns with the bottom of the frame. 

Installing the Rollers

Place the alignment aids into the cutouts. The rectangles have a slight chamfers so it helps to keep track of the orientation they were printed. Place the part that face the build plate into the slots. 

Apply some super glue onto the flat side of the roller and clamp on the other side. While drying you can add the bearing-fittings to the end points. 

Once the glue has dried you can apply the bearing to the end.

Now you can place the rollers into the spool holder. Unless you want to print the compatible dry box (Work In Progress) to mount the spool holder in you are now done!