HEVO-to-Voron (X/Y Axis)

*Progress halted - I now have a Vorn 2.4r2*

I built a standard Hypercube, HEVO, several years ago – I loved the build and the printer but was never happy with the sloppy X & Y axis with the steel rods and always wanted to replace them with linear rails. Then along came the Voron 2.4 OMG what a printer, but man what a price tag, and its little brother the Trident – OK but not as impressive as the Voron. Still not really in a position to do build a new printer but wait a minute I’ve already got a good % of the Voron gear I need – for X & Y and controls at least.

So, I came up with the mad-cap idea of replacing the X & Y axis with the Voron X&Y axis and keeping the HEVO Z axis & build table almost 100% untouched. There were a few snags with this plan though. My HEVO uses 3030 extrusion but the Voron 2.4 uses 2020, which means altering the majority of the Voron X & Y axis in Fusion 360 to work with 3030 extrusion. However, my Fusion 360 skills were very very poor. I’ve been working on them for other projects over the last 18months and got much much better, especially during this conversation.

Ultimately, I want to end up with a Voron 2.4 so concentrated on reworking those parts with a view to being able to reuse them in a full blown Voron 2.4.

My initial build was to use MGN15 rather than MGN9 linear rails as that’s what was available. Once the parts were reworked, I canned the project as they were at least 33% heavier than their 2020 counterparts and the extra weight would convert into ringing and other such issues. This then meant reworking the parts to use MGN9 rails.

Sadly, I didn’t really work the whole thing through and was very unhappy when I came to rework the X-Carriage to find it was impossible to get it to work with dual linear rails using 3030 extrusion. I’d invested a huge amount of time reworking these parts and was gutted, until I had another idea. Leave the X axis as 2020 extrusion which then meant I did not need to alter the X-Carriage (I’m using the version that uses the BLTouch)

OK, so off I go altering the Left and Right X axis joints to use 3030 extrusion for the Y axis and 2020 for the X. All goes well until I model my HEVO Z axis and build plate with the reworked Voron X & Y axis. The screws holding on Y axis linear rail carriage would hit the Z axis steel rod supports before the bed got to the hot end. So they needed to be reworked to reduce their height

Voron 2.4 parts

https://github.com/VoronDesign/Voron-2/releases/tag/V2.4r1

In the picture with highlight boxes Red highlight modified Voron parts Yellow highlight modified HEVO parts Modified Voron 2.4 parts, so far

A & B Drive Frame (Back Left & Right) - now uses 3030 extrusion

Cable Cover - had to move screwhead cut outs

XY Joint – Left & Right (Left & Right Gantry) - now uses 3030 extrusion for the Y axis

Front Idler Left & Right (Front Left & Right Idler) now uses 3030 extrusion for the Y axis

Modified HEVO parts, so far

Z Axis Linear Rail Bracket Left & Right Reduced height to the bare minimum

Changes to HEVO frame

Top back layer of 3030 extrusion is removed and shortened (or replaced with a shorter piece) then replaced with A & B Drive Frame at either end. This is installed 30mm below the top of the vertical frame, or any distance you prefer

The Z axis and bed are then moved so they are around 42-43mm below the X & Y axis

Print one of each part, in the orientation you find them, no supports are required except for Z Axis Linear Rod Bracket - Left & Right and you need 2 of each

If your Z axis lead screw is too long and interfers with the Y linear guide you may need to shorten it/them

Fusion 360 Model https://a360.co/3JJyWPL

The HEVO parts used for the Z axis bearing holders are not identical to the actual ones I have, but I could'nt locate the file. Should'nt be an issue as long as you check that the Z Axis Linear Rod Bracket Left & Right do not interfere with their travel

Update Feb 22 '22

Reworked the Fusion 360 model to better match my actual HEVO frame and build plate size. YMMV

Update Mar 5 '22

Added 5mm, 10mm, 15mm & 20mm Bed Bracket spacers. These may give sufficent room to use the standard Voron X&Y endstop