PB. MK4 Top and doors assembly

Step 1 Mouting the top cross-beam

On this step we need :

Prusa-box top

Crossbeam

Position the top cross-beam as shown and fix the cross-beam to the roof with 5 M4 screws and 5 M4 nuts (screw heads on the outside)

If you plan to add LED lights, don’t screw now the two extremities screws.

Step 2 Preparation of corner pieces

Take the 4 top corners: all parts are different.

Insert M4 nut in each of the indicated slots

Don’t forget to insert M4 nut on top slot (top back corners only)

If you will install the LED option, insert the square nuts on the front corner pieces (2 nuts per corner piece)

Step 3 Fitting the corner pieces (1/3)

Please note: each corner piece is different and has its own location.

Front right corner

Front left corner

Back right corner

Back left corner

Step 4 Fitting of corner pieces (2/3)

Slide the front corner pieces into place.

A little pressure may be required.

Printed part and steel frame must be align.

Fix the front left corner with 4 M4 screws.

Fix the front right corner with 4 M4 screws.

Step 5 Fitting of corner pieces (3/3)

Slide the back corner pieces into place. 

Fix the back left corner with 4 M4 screws.

Fix the back right corner with 4 M4 screws.

Step 6 Placement of the logo plate

Logo plate: left part

Logo plate: right part

Fix the plate to the roof of the printer-box with 6 M3x6mm screws. There is no need for nuts: this part of the printer-box will not be subject to any pressure.

Double check that the logo plate it on the right position: middle thicker part have to be closed to holes for top door hinges.

It is now time to add some mods if you want them!

Step 7 Assemble the “quick top remove” corners

You can skip this step if you printed classic corners

We are going to slightly bend this side of uprights. They all have this similar shape on one side.

Use the bending guide to make the shape. The metal frame must fit in bending guide’s notch.

This bending will create a spring effect, that will allow you to remove easily the top part of your enclosure.

You can follow these two videos :

• Metal bending
• Corners assembly

Slide the half corner in the bent upright like the picture.

Screw slightly, just to avoid loosing nuts.

Step 8 Installing uprights (1/3)

Left back uprights

Right back uprights

Turn the top of the printer-box over (outer side against the table).

Slide left rear upright from the top with printed corners inserted on the upright.

Then you can slide down the upright. 

You succeeded if left and right hooks are in place and there is no gap on the top.
If not, go back to (yellow arrow).

Tighten left rear upright with 4 M4 screws.

Tighten right rear upright with 4 M4 screws.

Depending on how the the corner pieces were printed, you may have to force a little.

Step 9 Installing uprights (2/3)

Place the roof on the back uprights that you assembled on the previous step.

The printed part on the top is a filament guide. It will be installed in Top spool holder chapter.

Step 10 Installing uprights (3/3)

Front right upright

Front left upright

Position right upright in front of  corner piece as shown.

Slide right front upright so that it clips to the top of the printer-box.

Fix right front upright with 3 M4 screws.

Fix left front upright with 3 M4 screws.

Step 11 Fitting the fixed hinges (1/2)

Start by sorting the fixed hinges:

Hinges type A

Hinges type B

Insert M3 square nuts in all hinges

Insert 3mm pins in all hinges.

Hinges should be inserted as showned.

Step 12 Fitting the back left fixed hinges (2/2)

Assemble hinges type B for the left door and on the inside, the vertical cable mounts using 4 M3x12 screws.

Assemble hinges type B for the front left door.

Assemble hinges type A for the front right, top, back and right doors.

Fix each fixed hinge with 2 M3x6 screws by screwing from the inside.

You can already install the webcam rail on the front-right upright part.

Step 13 Preparation of the Plexiglass sheets

Kit includes 7 plexiglass sheets (6 for upgrade kit):

2pcs for side doors 

1pc for back door

1pc for top door

2pcs for double front door

1pc for sealing of front door

Remove the protective films from the Plexiglas sheets.

Step 14 Preparation of doors printed parts and doors handles

 Hinges type A and B (4xA and 2xB in upgrade kit)

Top door handles (not in upgrade kit)

Front door magnet holders

Back doors locks

Front handles

Insert M3 square nuts into each slot

Step 15 Mounting back and top doors

Top door, check hinge and handle side regarding asymetrical distance.

Front and back doors are the same, check hinge and lock side regarding asymetrical distance.

Assemble 2 type A hinges with 4 M3x6 screws on those doors. Double check to fix it with screw head against table.

Assemble locks on back door with 2 M3x12 screws. Double check to assemble it with screw head against table.

Tighten the bolts of the locks sufficiently so that there is a slight resistance but not too much so that the lock is not too hard to open.

Step 16 Front doors

Position the two doors in order to have them like in the picture. Be careful about the asymetrical distance of the hinges.

Add on top of the right door, the plexiglass little part. It is used to seal the gap between doors when closed.

Tighten hinges and handles using M3 screws.

Add magnets inside magnet holder, and position them where they belong (see picture). Tighten them with M3x12 screws.

Step 17 Right door

Insert M3 square nuts into each slot.

Insert 6 magnets into the big slots: don’t hesitate to slightly push them at the bottom of the slot.

Put on the table all parts as shown on the picture: all writings must be against the table.

Be carefull to R2 orientation : handles and growth must be on the outside.

Place the Plexiglass sheet on top of it, and screw lightly using M3*12 screws. If you screw to hard, you might bend the sheet.

Step 18 Left door

Insert M3 square nuts into each slot.

Insert 6 magnets into the big slots: don’t hesitate to slightly push them at the bottom of the slot.

Put on the table all parts as shown on the picture: all writings must be against the table.

Be carefull to R2 orientation : handles and growth must be on the outside.

Place the Plexiglass sheet on top of it, and screw lightly using M3*12 screws. If you screw to hard, you might bend the sheet.

You have successfully assembled top and doors