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Zero G Mercury One.1 (Ender 5 Plus) enclosure top hat

This is the top hat for Ender 5 Plus converted to Zero G Mercury One.1 3D printer.

photo front view back view

Idea

The main idea behind this top hat was to be able to make it at home with as little special instruments as possible, thus there are some downsides of this design (e.g. it currently supports only 2mm top acrylic/PC panel).

  • You can buy any 2020 extrusions and cut them with a home-made or a simple 90 degrees angle jig.
  • You can cut acrylic panes by a scraper/exacto knife.
  • You will need to drill not many holes in the acrylic top panel, not to worry with acrylic cracking druring the drilling process (side panels are mounted by a VHB tape, which also adds more insulation)

My tests show that I'm able to get stable 47-49C in the hat itself in about 25-35 minutes.

This top hat was hugely inspired by Vez's VzVot design.

BOM

Item Amount Notes
2020 aluminum extrusion 594mm 2 Frame mounted side extrusions
2020 aluminum extrusion 574mm 2 Top hat's side extrusions
2020 aluminum extrusion 578mm 2 Top hat's front and back
2020 aluminum extrusion 195mm 4 Top hat's vertical legs
2040 aluminum extrusion 578mm 1 Frame mounted rear extrusion
M3x8 BHCS 26 Bolts, used to mount printed frame covers from the sides
M3x10 BHCS 16 Bolts, used to mount printed frame covers from the top
M5x8 SHCS 4 Bolts, used to mount a hinge to the top hat's frame
M5x12 SHCS 14 Bolts, used to mount handles and to mount lower part of the hinge to the frame
M5x80 SHCS 2 Axes for hinges
M5x8 BHCS 2 Bolts, used to mount frame mounted extrusions
M5x12 BHCS 2 Bolts, used to mount frame mounted extrusions
M5x16 BHCS 12 Bolts, used for blind joints and to attach back of the frame mounted extrusions
M5 lock nuts 2 Nuts to fix axes
M3 T-nut 42 spring loaded t-nus are better, but normal ones work too
M5 T-nut 20 spring loaded t-nus are better, but normal ones work too
5mm VHB tape

Build guide

Print plastic parts

;)

All outside parts can be printed in PLA, but ABS is always more preferrable.

Cut your extrusions to the length

Note You can skip the step if you have your extrusions pre-cut by a supplier

Tap your extrusion for blind joints

Note Watch a great video by Nero3D about blind joints if you aren't familiar with the concept*

Warning Use 5mm tap if you have ~4mm inside diameter in you particular extrusions, or 6mm tap if you have ~5mm internal diameter in you extrusions.

You need to tap 10 holes.

TODO: IMG here

Drill access holes for blind joints

Warning Use 4mm drill bit to make access holes for M5 blots, or 5mm drill bit to make access holes for M6 bolts.

TODO: IMG here

Assemble the top hat's frame

TODO: IMG here

Assemble the frame mount for the top hat

TODO: IMG here