Wanhao i3 / Maker Select v2 Filament Runout Sensor with BLTouch Mount

 A filament runout sensor mount for Wanhao Duplicator i3 / Maker Select v2 printers with integrated BLTouch mount.

It is designed for a standard roller lever bump switch, I use a MBB1 switch from PTR Hartmann.

The Mount attaches to the original fan mount screws. If you don’t use the original part cooling fan, you can use the original mount with some nuts.

With this mod, the max. printable Z-height will be limited to 130mm, but I personally never print this tall. See last picture. You might want to limit the Z-hight in your slicer.

You can route the switch wire though the original drag chains, or simply zip tie the cable to the outside of the chain every few links.

The switch can for example be wired to a raspberry pi running octoprint, just search for the “filament runout reloaded” plugin to get started.

If you use the BLtouch, here are the probe offset values you need to set in your firmware or via gcode M851 (save with M500):

X: 52.00 Y: -46.00 Z: -0.55 (mm)

You might need to adjust the Z-offset depending on your nozzle etc.

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Printing:

The assembly consists of 3 parts: the base, the arm, and switch mount.

Print all files with the flat side down.

Recommendation: Print the base and arm in 0,2mm layer height without supports and the switch mount with 0,1mm layer height with supports touching the buildplate.

PLA works fine, PTEG might be more stable

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Hardware needed:

• 4x M3 Nut
• 2x M3 x 10 mm flat head bolt
• 2x M3 x 16 mm flat head bolt
• 2x 2 mm x 10mm small wood screw
• Original BLtouch mounting screws
• 100mm 4mm ptfe tube

Imperial hardware might work to, cant test.

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Assembly:

• Insert the M3 nuts in the hexagonal cutouts, might need pliers to press them in.
• Screw the arm to the base using 2x M3 x 10mm flat head bolts.
• Insert switch in the switch holder and screw it to the small holes with the wood screws.
• Solder the switch wires to the switch.
• Screw the switch holder to the arm with 2x M3 x 16 flat head screws.
• Push in the ptfe tube in the top, bend it slightly towards the base to create clearence to the frame of the printer.
• Screw BLtouch to the mounting holes on the base with the supplied bolts.
• Remove original fan screws and filament form the hotend.
• Insert the mount above the printhead.
• Screw the fan back on with the screws going thru the base. 

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Usage:

• Insert filament in ptfe tube and feed it thru the switch mount.
• make sure, the switch activates. If not, bend the switch lever slightly.
• press the lever on the hotend down to feed the material in, like normal.