Instructions

Mounting the Mk7/Leapfrog Creatr spring loaded idler

This instruction shows you how to remove the existing extruder from your Leapfrog Creatr and replace

it with the spring loaded design.

Note that changing the design of the Creatr my void your warranty.

No original parts are modified for this upgrade so you can always restore the Creatr to its original state

when it needs to be shipped to Leapfrog for service.

Tools needed

Note that the M4 nut needs to be a thin nut of max. 2mm. These are not widely available, you can also

take a standard nut and file it down to the needed size.

Preparing the printed parts

Make sure surfaces are smooth, drill all holes up to 3 or 3.2mm.

Remove any filament from the extruder before starting.

Remove the two screws that mount the fan-guard:

Carefully remove the plate from the carriage by wiggling it back and forwards. The aluminum plate has

a tight fit and may even be held in place using some Loctite. By tilting the plate both horizontally and

vertically it will eventually come loose.

Now the carriage should look like this:

Remove the two screws, this will remove the cooling plate and the stepper motor. Note that the

aluminum block that is mounted directly on the carriage should not be removed.

Remove the ball bearing and keep it together with the two washers, these will be used in the new idler.

Mount the ball bearing in the new idler

The ball bearing and the two washers from the original extruder are placed inside the hole in the idler

part. It is OK when some force is needed to squeeze the washers in between. When you are scared

about breaking the part, just file away a bit more material until everything just fits.

Use the M4 x 15mm screw and the thin nut to keep the ball bearing in place.

Optionally, use some medium strength Loctite to prevent the nut from loosening.

Mount the idler on the stepper motor

Take the picture below as a reference of what the final construction looks like:

Temporarily place the fixed block and the idler and mount them on the stepper motor.

play between the motor flange and the nut as shown in the picture below. If this is not the case, remove

the nut and file it down a bit more.

mounted with two nylon washers between the fixed block and the guide on top.

another washer on the right side. Move the guide that sits on top in place and put the second screw in.

You may now mount the spring but this can also be done at the end when the motor is fixed to the

carriage.

Mount the stepper motor on the carriage

Start by reinstalling the cooling plate and the two screws on the cooler block that hold the hot end:

Place 5 washers on each screw to get a 4mm spacer. Now mount the stepper motor on the screws and

check that the input hole of the hot end aligns with the hobbed wheel of the extruder.

Your construction should now look like this:

Mount the fans

Place the front plate that holds the fans back on the carriage and gently push it in place. Tighten the two

screws. If the mating plate came loose while mounting the new extruder, hold it in place by hand.

First switch on the extruder (hot end) and feed the filament through the feeder tube, make sure the

filament sticks out far enough to be able to push it in the extruder.

Now feed the filament through the feeder hole until it stops on the hobbed wheel. Gently push the latch

downwards until you can slide the filament further in. This makes sure the hobbed wheel guides the

filament into the hot end.

You should now be able to push the filament in a good 40mm or so before you feel any pressure.

When the extruder reached its operating temperature you should be able to push the filament in by

applying a bit of force. You should see an extrusion coming out from the nozzle.

Removing filament from the extruder

With the extruder still hot, push the latch downwards and pull the filament out of the extruder. You