Now with Helper Tool! Enclosure upgrade for easier maintenance left side door conversion kit with with magnets and minimum work needed

NOW with Helper Tool! Just place it on the panel, insert M3 screws and mark cut lines and drill points!

Tired of reaching your hand through entire enclosure to disconnect or remove PSU for maintenance? 

This is for original Prusa enclosure for MK4/MK3 and so on.

This kit allows you to turn your side panel into a fully open 180° door for easier maintenance of your printer with minimum altering in mind.

It requires however cutting and drilling your existing panel or ordering a new plexi or whatever. Hinges are made for original 1.5 mm side panel thickness.

BOM:

• magnets 20x10x2 mm 6pcs
• M3x20 bolts 4pcs
• M3x8 bolts 5 pcs 
• 3mm wood drill
• 6mm wood drill
• temporary M3x8 or longer 6 pcs (for profile assembly alignment)
• 3mm nylon spacers (optional)
• 9-10 mm double sided LED tape (the thinner the better) for example this one https://www.amazon.com/Rextin-Meters-Adhesive-stronger-adhesive/dp/B01FH3S4V6?th=1
• a new 1.5mm plexiglass panel from a CNC maker of your choice if you want to leave your existing one unaltered (optional)

Panel altering procedure:

1. This will permanently alter your existing panel but it will still remain mountable if you wish to return to your previous state.
2. Read everything first. Look at the pictures too.
3. Assemble hinges with M3x20 bolts.
4. Remove your left side panel.
5. For drilling, attach assembled and closed hinges to the existing left side holes of your panel with M3 bolts and use 3mm wood drill for door hinges holes.  
6. Don't remove M3 bolts yet. Mark lines for where the panel fits into a 1.5mm thick pocket in door hinges.
7. Use a 300+ mm ruler or whatever to make marks on the panel surface in straight line for both upper and lower hinge for better dimension accuracy.
8. With 3mm or less wood drill holes in corners of your cuts, this is to make sure you don't break the whole panel when making cutouts.
9. Use blade for making cut lines on the surface of the panel.
10. Break short edges first, then break long ones.
11. Use 6mm wood drill for enlarging two holes in a panel where top profile fits. This is for enclosure left handle bolts heads to fit through when closing door.
12. Assembly hinges to the frame and assembly cut and drilled panel to the hinges with M3x8 bolts with 3mm nylon spacers between bolt head and panel glass.
13. Place M3x8 bolts into profiles for alignement and use double sided tape to assemble top, bottom and side profiles.
14. Let the adhesive sit with door closed and magnets doing the job for you.
15. Remove M3 bolts. You can leave one M3x8 bolt in the middle of a side profile for better door support.
16. Enjoy your easier printer maintenance from the side.

Printing instructions for MK4S:

• preferably use at least PETG or PCTG
• 0.2mm layer height
• 2 perimeters
• 5 top 4 bottom layers
• 10% adaptive cubic infill because it's cool (or imo underrated 3d honeycomb)
• at least 3mm brim with 0.7mm spacing
• mind magnets force when altering parts placement on the build plate
• pause 1 for placing M3 nuts into panel hinges pockets
• pause 2 for placing 20x10x2 magnets into profile pockets

TODO:

• additional panel profiles with smaller magnets for better door stability
• drilling 6x3mm pocket in a bottom of the handle for a M3 flathead hex bolt and a profile for a small magnet to attach to the handle bolt when closing door

I have also uploaded FreeCAD fcstd model files if you like to tinker with things.

I hope you enjoy this upgrade if so leave a like and let me know in comments if you like my project or post a make.