Front Mounted Ender 5 Power Switch

What is it for?

While upgrading my Ender 5 to use a Manta M4P, I mounted all the electronics on the rear of the printer, but I needed a way to keep the power switch on the front of the printer for easy access.

Compatibility:

Designed to fit the standard Ender 5 power switch, although you'll need to lengthen the wires (more on that below).

Compatible with dbltrbl023's Ender 5 Frame Brace (95mm or 135mm versions only). The pictures show the switch installed underneath the 95mm version.

Required Hardware:

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• 4x - M5-10 screws
• 4x - M5 drop-in T-nuts
• Approximately 5 feet  - 14Ga silicone wire (red).
  • alternate option - if you'll be doing more wiring in the future.
• 3x - covered disconnect terminals
• 1x - ring or spade terminal
  • I use this multi-pack, and add clear heatshrink to cover my disconnect terminals.
• Terminal Crimper

Instructions:

WARNING: You will be working on wires that carry mains-voltage. Do not do any of this while the printer is plugged in, and observe all possible safety precautions. I am not responsible if you or somebody else is injured while modifying your printer, or if you make something that is un-safe, even if you follow my instructions perfectly.

This are a work in progress, and need more pictures and steps.

1. Print the STL file
   1. I used 0.2mm layer height, 2 perimeters, 3 top and bottom layers, and 20% infill)).
2. Cut the two lengths of wire you need to go from your switch to your power supply.
   1. If you're doing my Ender 5 conversion, the lengths are approximately 35" for both wires.
   2. Create Wire A:
      1. On one wire, crimp a disconnect terminal on both ends. 
      2. Cover both terminals completely with clear heat shrink tubing if it's not already a covered terminal. 
      3. Ensure the insulation is flush with the open-tip of the terminal, fully covers the metal portion, and extends all the way onto the wire.
   3. Create Wire B:
      1. Crimp a disconnect terminal to one end, and a fork terminal to the other.
      2. Cover the disconnect terminal (if it isn't already) the same as before.
3. Mount the power switch housing to the printer frame.
4. Pre-mount the wires to the switch (not required, but it's easier)
   1. Attach one end of Wire A to the spade behind the “O” on the power switch.
   2. Attach the disconnect terminal of Wire B to the spade in the middle of the switch.
5. Fish the wires through the front of the power switch housing, and click the switch into place.
6. Route the wires along the inside of the frame using cable clips, and wire the other ends of the wires to the power plug, and the L-input terminal of the power supply.