Nesco Filament Dryer (FD60) - 5 gallon bucket adaptation

I have seen a few filament dryers out there that require you to cut the trays apart on a dehydrator.  I have also seen the 5 gallon bucket versions.  The adapter rings on those usually causes turbulence because the heat comes out at the ring edge.  This model uses a gradually slope to help to force the hot air down.  I also incorporated into the design the same size slots on the bottom of the bucket to match the original dehydrator to allow moisture to escape.  This design allows you to still be able to use the dehydrator for its original purpose as there is no need to modify any part of it.

This is designed around the Nesco Dehydrator (FD60) that are 13-7/16" diameter.  Verify before printing because if your dehydrator is not this diameter it will not fit properly.

What you will need for this project.

1. PETG filament.  It will hold up best over time, however you can use whatever you pick
2. #6-19 Thread forming screws for plastic (16)
3.  1-½" Schedule 40 PVC (length depends on your bucket)
4. (8) Bucket to Dehydrator Adapter Prints
5. (1) PVC to Dehydrator Air Inlet 
6. (16) 0.25" x 0.45" Printed alignment pegs 
7. Superglue

Print settings - 0.2 layer height, speed profile, no support, brim, 20% infill, vertical shell perimeters - 4

Print the bucket adapters, you need 8

Print the pegs.  I used the Add Shape feature in Prusa Slicer to make these.  

Print the PVC Adapter

Insert the pegs into each of the bucket adapters on one side only (same side in same orientation).  Apply super glue to one side only, slde adapter together and secure with 2 screws.  Repeat this process until the ring adapter is complete.

Cut your PVC.  I hesitate to tell you the exact dimension as not every 5 gallon bucket is the same height between manufacturers.  What you want is for the PVC Adapter to just seat on the bottom the dehydrator.  This crucial for proper air circulation.  With my FD60, if I lay a level across the bucket adaptor installed on top of the bucket, the PVC is 5/16" shorter than the measured distance from the inside bottom of the bucket to the bottom of the level.  I recommend cutting the PVC with a miter saw so the cut faces are square.  

Next draw 4 lines on the PVC lengthwise 90° apart.  Use a straight edge or roll the PVC up against your level.  Label them 1, 2, 3, 4.  Mark lines 1 and 3 every 2" starting at 1".  Mark lines 2 and 4 every 2" starting at 2".  Drill this out with a  5/16" or 3/8" bit.  A center drill works well here but can be done with any drill bit.

Take your original dehydrator bottom and turn it upside down.  Set the 5 gallon bucket on it.  Transfer the hole openings from the original bottom to the 5 gallon bucket.  Shine a flashlight into the bucket so you can see the bottom.  Drill the endpoints with a 3/8" drill bit so the hole will be a the same level as the bottom.  Use masking or painters tape from hole to hole at the top and bottom each set of holes.  Carefully cut out the section so you end up with a slot.

You can use whatever you wish to seperate the filament rolls in the dryer bucket.  3d Print pegs or if you have something that is the same height, use it.  The first one in should not be laid directly on the bottom of the bucket.

• Place Bucket Adapter on top of bucket
• Place the filament inside and centered in the bucket with spacers inbetween
• Place the PVC inside the filament spool center
• Place the PVC to Dehydrator adapter on top of PVC
• Place Dehydrator on top or Bucket Adapter.

Dry away

note - if you want to glue the PVC in place to the bottom of the bucket, that is up to you.  I elected not because if I ever need to change dehydrators to a different model, I can still you the bucket.