CoreXY conversion for Ender 5 S1 printer

Warning:

This is a project that is in progress, and subject to change. While the printer is working with these parts, I am constantly improving it and may post updates at random intervals. I will try to increment the version number so you can see it has changed from your download.

To mount a BTT 5" touch screen and Raspberry Pi as part of this upgrade please see model https://www.printables.com/model/1013730-klipper-screen-modification-for-ender-5-s1-printer.

 I am planning to merge this motion system into a tophat that will fully enclose this printer. The lack of a full closed base is delaying that project right now as I figure out how to seal the bottom.

Background:

When I first acquired this printer, it appeared to me that it had an extremely heavy motion system with large heavy rubber wheels with bearings on x and y axes, and heavy metal parts on both x and y axes and the print head. I wanted to reduce the weight to improve print quality and perhaps speed as well.

I have created a corexy conversion for the E5S1 printer. The major parts for the motion system are here, there is an additional listing coming to document the Klipper conversion and to mount a 5" display screen inside the printer where the original control screen (disabled when you upgrade this printer to Klipper so I removed it) was mounted.

This conversion does away with the rubber wheels for the original motion system and substitutes linear rails. The original metal trolley is replaced with a 3d printed plastic part for additional weight savings. I also replaced the extruder with a Micro Swiss NGTM Direct Drive Extruder.  The original 370mm z axis lead screw is replaced with a 400mm unit, and this conversion adds about 25mm to the z axis travel.

The reason I designed my own conversion is because I had intended when I designed this to add a multicolor filament switching system to this printer, so I wanted the belts running across the front of the printer instead of the back where most Ender 5 comversion designs placed them.  That multicolor unit is still under development in Greece, search for CoPrint if you are interested.

The stock wiring harness mostly works for this conversion although I had to pull it around a bit.  The stock endstop sensors are used, there are mounting points on the right motor mount for the y endstop and on the print head trolley for the x endstop.

Most of this upgrade is fastened to the original top rail of the Ender 5 using 3mm and 4mm t-nuts and various length screws.  There are a few heat set nuts as well, and 5mm (6mm?) screws into the ends of the x axis 2020 rail tapped hole.

Printed Parts:

There are 7 major printed parts for the motion system.  Two motor mounts that sit in the back corners of the printer, two pulley brackets in the front corners, 2 x-y axis joiners that sit on the y axis rails and hold the x axis rail, and the trolley that mounts around the x axis rail.  There is also a small part that mounts the CR Touch sensor to the print head.  I would love to get that closer to the nozzle, but I have not yet found a way to do that with the geometry of the geared extruder.

Major Purchased Parts:

3 300mm MGN12 linear rails
1 350mm 2020 aluminum profile rail
2 Twotrees Nema 17 Stepper Motor Bipolar 1.5A (17HS4401)
1 Micro Swiss NGTM Direct Drive Extruder
1 400mm（15.75 Inches）Tr8x8 Lead Screw for the Z axis
1 PEGATISAN Webcams Computer Camera HD 1080P Eye Contact Camera
Lots of fasteners - list coming.
Cable for the extruder motor
Cables for the hot end fans

<expanded parts list with links coming>

Detailed Instructions:

<coming soon.>