Beacon 3D mount solution for E34M1 - EVA 3 for Mercury One

Obsolete:

I have made this as slim variant by introducing compromises (mainly soldered cable directly to PCB). Since then I have redesigned this to more modular solution and I strongly suggest to use variants here E34M1 . They do support external routing of USB cable and it is plug-in solution not solder on PCB.

But for the brave or if you still need to save space …

Disclaimer:

If you have not brought unassembled Beacon3D, you will not be using connector and will be soldering the wires directly onto PCB. Or you can use low profile and desolder connector. Please consider your capabilities to do so (micro soldering iron, desoldering pump at least, some motoric skills). You could end up with broken Beacon3D probe.

Notes:

For the assembly we will use low profile Beacon 3D variant without connector. Instead of using connector the cable is to be soldered directly onto the PCB.

The cable is routed behind the 5015 fan straight through the back plate's ducts.

There are two versions of horns:

• bottom_horns_beacon.stl does not require additional hardware and the screws gets screwed straight to the plastic
• bottom_horns_beacon_fi requires additional M3x3mm aka short heatset inserts.
  ⚠ Be EXTRA careful with inserting them into horns. The wall directly below is really thin and using straight solder tip will penetrate the wall way before seating the insert properly. So if you're not using special heatset insert tools (and maybe even these would have too long tip - the tip must not ertend through outside the body of the insert), screw the M3x6 into the heatset and apply the heat though it during insertion.

Recommended order of assembly:

Inspect and file/sand the cable hole going through the back plate. The dimensions are really tight so try to make it as smooth as possible.

Unless you have the unassembled Beacon3D, you need to remove the connector that is soldered onto PCB. Remove it carefully and clean up the excess solder.

Push the cable through the backside hole leaving nice amount of slack for further maneuverability (you'll need extra free length it during soldering).

Dry seat the heatshrunk isolation into cable strain and measure the wires so that they would have slight slack after soldered onto PCB. Cut them to desired length - see photos that illustrates how the cable is soldered/seated. Solder it to the Beacon PCB, see pin details and coloring on Beacon site.

Attach Beacon to the Horns with M3x5mm screws.

Screw together the horns and back plate with M3x8mm.

Seat the narrower end of heatshrunk isolation into cable strain on the bottom of back plate. Then carefully start pulling the cable out back the hole to bent it in tight radius thus being seated firmly and protecting the solder joints from being ripped off.

BOM:

1x M3x8mm

2x M3 screws - shorten the ones that comes with Beacon 3D or M3x5mm low head profile screws (can be pricey)

1x Beacon 3D probe - unassembled or low profile

Optional for bottom_horns_beacon_fi

2x M3x3mm aka short heatset inserts like https://cnckitchen.store/products/gewindeeinsatz-threaded-insert-m3-short-100-stk-pcs

Schema

The distance from nozzle to the beacon in Y is 23.3mm

.cfg:

[beacon]
x_offset: 0
y_offset: 23.3

Proof of concept of back and horns that are usable with Beacon3D probe.