Voron 2.4 LGX Lite Extruder Mod

Overview:

This Voron modification to the Stealthburner option supports the Bondtech LGX Lite extruder,  ERCF Filament Sensor, and the Hartk 2 Piece Toolhead PCB.

I purchased the Bondtech LGX Lite extruder hoping that it would provide a more reliable filament feed to the Dragon High Flow Hot end during high feed rates.  The printer is equipped with a ERCF Multi Material Filament feeder which adds some additional drag, thus requiring a more advanced extruder.

I intended to use the Hartk 2 Piece Toolhead PCB for cable management to ease toolhead maintenance while in production.

Unfortunately the LGX Lite is slightly larger compared with the Stealthburner preventing mounting it to the extruder body.  I found two potential solutions for mounting a PCB and Providing filament sensing.  Ramalama2 has a mount that screws to the extruder.  The PCB screws to the mount.  Unfortunately this solution does not support a filament sensor.  Eytecz's solution supports a Hall Effect filament sensor but only a single PCB making servicing difficult.  Hall Effect is tricky to initially tune and is temperature sensitive.

Revised Design:

I combined the two referenced solutions by modifying Eytecz's PCB mount to accept Hartk's 2 Piece Toolhead PCB and sourced a different Fan mounted PCB.  See BOM.  This board has the connector positioned fully outboard that mates with the main PCB without any side loads. The Hartk fan board connector is positioned a few mm inboard and will not mate with the main board.

Note:

The PCB main board mounts to the front body rather than to the extruder.  I found a number of clearance issues with mounting the PCB to the extruder largely do to the mount's thickness.  Installing the PCB on the front mount does not require a separate PCB to extruder mount saving 4mm for additional clearance.

I also modified the Cable cover to add additional clearance above the top 3 connectors.  This existing cover would touch the connectors leaving no room for the wires.  The cover is still a little tight at the rear connectors but it bends enough to allow the lock to fit.  In the future I may increase the clearance a little in this area.

Also included is a copy of the Stealthburner Fan/LED cover.  It is outwardly identical to the original but the interior is modified to provide necessary clearance for the new Fan PCB.

I included files for both the Hall Effect and Omron version of the filament sensor switch.  I recommend the Omron switch version because it is absolutely fool proof and is not subject to temperature drift.  Only the “Front” and "Rear" files differ depending on the FS you choose.

BOW:

I am listing only the items that differ from the Stealthburner mod.  If you are building the printer from scratch, refer to the Stealthburner mod for additional material requirements.