November 1, 2012 AT 4:00 am

John Abella’s Supersizes His Replicator #3dthursday

One of the best things about Open Hardware plywood-case 3D printers, mills, lasers, plotters is how easily they can be customized. John Abella, organizer of 3D Printer Village at World Maker Faire and a veteran 3D printer builder, transformed his MakerBot Replicator into an impressive custom (Unofficial) Replicator XL by cutting his own case, taking care to document his disassembly and re-assembly, and working with a number of talented software/firmware folks (especially DNewman & Jetty) to make the necessary adjustments to accommodate the increased build volume.

This isn’t a hard process, but it’s also not a one hour job. I had to lengthen at least a dozen wires (stepper power / fan power / extruder heaters) by a few inches. The thermocouple, HBP, and endstop wires on mine were all long enough.

The case design DXF files on Thingiverse for the Replicator are WRONG. These are not the production files – and it messed me up a bit. The mightyboard power / usb / reset button location has moved, requiring some dremel adjustments. On the files I uploaded I think I’ve resolved it, but haven’t tested it yet. You might have to dremel these sections a little still.

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