Mercury One.1 Full Assembly
We’re now going to be working on the left_front_tower.
Left front tower
If you’re looking for a video instead of text and images, check this out: https://www.youtube.com/watch?v=abdkMgndM9Y
hardware
| Type: Amount: | 5x30 Precision Dowel pin 1 |  |
| Type: Amount: | M5X20mm 1 | placeholder |
| Type: Amount: | F695 Bearing 2 |  |
| Type: Amount: | M5 Shims 3 |  |
| Type: Amount: | M3 Heatset 1 |  |
Printed parts
| Type: Amount: | Left front tower 1 |  |
| Type: Amount: | Front tower tool 1 |  |
Left front tower assembly
Inserting the heat set
Don’t burn yourself! We’re going to work with a soldering iron, be careful. Heatsets inserts are still hot after melting them into the plastic, don’t touch them!
The front of the tower has one hole that is used for a heatset. This heatset helps to pull the belts tight during the full assembly.
To insert the heatset, use a soldering iron and make sure to insert it flat so that the front tension plates do not need to be angled during assembly. This helps to address any potential misalignment of screw holes.
The image below shows the heatset melted into the part. Please note that it sits slightly below the surface so that it does not pull out during use. Make sure to follow the same technique when inserting the heatset to ensure proper alignment and functionality.
Building the flange stack
It is now time to add the flange stack, and we will be using a helpful tool to assist us in the process.
We have two tools available for adding the flange stack: one for generic 5M shims (1mm thick), and the other for brass shims or washers that may be included in some kits.
Below are two versions provided, one for regular 5mm shims and another for brass shims. The visual distinction between them is the locations where the shims are placed. More details will be explained further down.
We will be using the following hardware for this section:
| Type: Amount: | Front Tower Tool 1 | |
| Type: Amount: | M5 Shims 3 | |
| Type: Amount: | F695 Bearing 2 | |
Let’s begin by obtaining the Front Tower Tool, which is the printed component displayed above. Ensure that it is positioned in the same manner as shown in the image.
We will now insert the bearings with the flange in the deeper groove. It’s important to note that this can only be done in one way. Ensure that the bearings are pressed in as deep as they can go, so that they will line up with the dowel pin later and will not fall out.
Repeat the same process for the other bearing.
We’re going to be installing the first shim. To make this process easy, you just drop it in the center in-between both F695 flange bearings. You can tap your finger on the top of the bearing to make it fall in the perfect spot
Next, we will drop the other two shims on the sides. These shims may fall out, so be careful when placing them. To make the process easier, you can grab the front stepper tower and lower it around the tool once everything is set down they won’t fall out. Refer to the following images for guidance.
Lowering the front tower
| Type: Amount: | 5x30 Precision Dowel pin 1 | |
| Type: Amount: | Left front tower 1 | |
| Type: Amount: | Complete flange tool 1 | |
To continue, lay down the complete flange tool from the previous step. Then, grab the left front tower and lower it over the complete flange tool. This will help to prevent the shims from falling out of the side.
For better stability, lay the front tower flat on the table when lowering it over the complete flange tool, even though our picture shows it upright.
Now grab the dowel pin and start pressing it into the hole on the top. When pushing it into the flange tool you might have to wiggle it a little to get it in properly. Also make sure in advanced to test fit your pins in the flanges, if they don’t fit. Sand them down as displayed in the menu on step 5.
As shown on the image below, the pin should be pushed all the way down into the hole on the top. The pin doesn’t sit flat on the top but is recessed, as highlighted in red below.
You can now remove the flange tool, the flange stack stays on the dowel pin. It can be though to remove, don’t break any fancy nail.
Final steps
| Type: Amount: | M5X20mm 1 | placeholder |
One of the final steps, this is probably the easiest… Take the M5X20mm screw and drop it into the single hole that’s left on top.
Make sure it’s pushed down all the way, this will make it easier for final assembly in a later step.
Congratz, your part should look like this: