Assemblling the Prusa INDX Core one with the Gen 2 upgrade

If you received your Prusa CORE One INDX conversion kit with the Prusa CORE One+ Gen 2 upgrade, or bought the Gen 2 upgrade separately and want to install both at the same time, this article will help you with the process. Read the instructions and information in this article thoroughly.

If you received the CORE One+ GEN 2 upgrade as part of your Prusa INDX conversion kit, note that all the GEN 2 upgrade parts are included in the UPGRADE box.

Securing the bed spacer - right, additional information

Follow the Prusa INDX guide from the start.

Keep following the instructions in the Prusa INDX guide until you finish step SECURING THE BED SPACER - RIGHT, then read the instructions below in this article: 

Before you move on to the next step in the Prusa INDX guide, we need to disconnect the X and Y motor cables and remove the left side panel and cover from the printer to accommodate the GEN 2 upgrades.

Follow the instructions below:

• Press the safety latch to disconnect the X and Y motor cables from the xBuddy board on the back of the printer.

• Gently pull the X and Y motor cables slightly to create some slack while keeping the connectors inside the electronics compartment.

• Remove all five nylon rivets securing the left top see-through side cover. Support the cover by hand when removing the last rivets to prevent it from falling.

• Remove the side cover from the printer and set it aside in a safe, clean place.

• Remove the eleven nylon rivets securing the left side metal panel. Support the panel by hand when removing the last rivets to prevent it from falling.

• Remove the metal panel from the printer.

Once the motors are unplugged and the left panel and cover are removed, return to the Prusa INDX guide step REMOVING THE REAR BED SPACER, and continue from there.

• You will notice that the left panel and side cover are still in place in the Prusa INDX conversion guide. Proceed as if the left side cover and panel were removed in the Prusa INDX guide.

Keep following the instructions in the Prusa INDX guide until you finish step SECURING THE OFFSET SENSOR CABLE.

Removing old expansion joints

Switch to the GEN 2 guide, step REMOVING OLD EXPANSION JOINTS, and continue from there. 

• You may note that the headbed in the GEN 2 guide is leaning on the back of the printer. Follow the instructions as if the heatbed assembly was removed; it does not affect the heatbed expansion joints installation. 

Keep following the instructions in the GEN 2 guide until you finish step INSERTING THE HEATBED SPACER.

Removing the Bed-cable-cover-bottom

Return to the Prusa INDX guide, step REMOVING THE BED-CABLE-COVER-BOTTOM, and continue from there.

• The old expansion joints are visible in a photo in the Prusa INDX guide. Proceed as if the expansion joints were replaced.

Keep following the instructions in the Prusa INDX guide all the way until you finish step RELEASING THE BELTS, then read the instructions below in this article:

Additional information and removing the belts

Before you move on to the next step, we need to remove the right side panel and side cover from the printer to implement the GEN 2 upgrades.

Follow the instructions below:

• Remove all five nylon rivets securing the right top see-through side cover. Support the cover by hand when removing the last rivet to prevent it from falling.

• Remove the side cover from the printer and set it aside in a safe, clean place.

• Remove the eleven nylon rivets securing the right steel side panel. Support the panel by hand when removing the last rivet to prevent it from falling.

• Remove the metal panel from the printer.

With the right side panel and cover removed, read the information and instructions below in this article before proceeding:

The PTFE tube leading to the filament sensor is removed in the Prusa INDX guide, but is visible in the GEN 2. guide. 

The Bowden-guide is visible in the photos. It is also attached back onto the motor assembly in the GEN 2 guide. We will not need it for the Prusa CORE One INDX conversion process; you can remove it from the printer once it is detached from the motor mount.

Belt-tensioner screws:

During the upcoming belt exchange instructions in the GEN 2 guide, we recommend using the Prusa lubricant found in the Fasteners 2/2 bag in the Prusa CORE One/+ INDX conversion kit.

• Apply a small amount of Prusa lubricant to the tip of both left and right M3x30 belt tensioning screws you removed earlier.
• Spread the lubricant evenly around the entire thread and insert the screws back into the belt tensioner.
• Skip this step when it later appears in the INDX guide.

Switch to the GEN 2 guide step REMOVING THE BELTS, and continue from there.

Keep following the instructions in the GEN 2 guide until you finish step GUIDING THE UPPER BELT (GANTRY-RIGHT).

Gantry aligner tool

Return to the Prusa INDX guide step GANTRY ALIGNER TOOL: PARTS PREPARATION, and continue from there.

• You will notice that the right panel and side cover are still in place in the Prusa INDX guide for now. Proceed as if the right side cover and panel were removed in the Prusa INDX guide as well.

Keep following the instructions in the Prusa INDX guide all the way until you finish step COVERING THE FS - RIGHT.

Mounting the side panels, PTFE and right cover

Before you move on to the next step in the Prusa INDX guide, we need to attach both of the top see-through side panels.

Follow the instructions below:

• Use four nylon rivets to reattach the left top see-through side cover. Do not insert a nylon rivet into the top middle hole. This is where we will mount the filament sensor in the Prusa INDX guide later.

• Mount the right top see-through side cover. If you have the 8-tool version of the Prusa CORE One INDX, do not insert the top-middle nylon rivet as well.

With both top see-through covers mounted back, continue following the Prusa INDX guide step PTFE TUBES - LEFT SIDE: PARTS PREPARATION, and continue from there.

Keep following the instructions in the Prusa INDX guide until you finish step SECURING THE ZIP TIES II.

Fixing the heatbed

Switch to the GEN 2 guide step: EXPANSION JOINT ALIGNER, and continue from there.

Keep following the instructions in the GEN 2 guide until you finish step FIXING THE HEATBED.

Mounting the left cover,  covering the electronics

Now that the expansion joints are aligned, let's return to the step we skipped in the Prusa INDX guide and secure the offset sensor assembly by tightening the M3x10 screw. 

The screw forms its own thread in the plastic. Do not overtighten.

• You will notice that the right-side cover is still in place in the photo above. Proceed as if it were not there; it does not affect the process.

Once the heatbed is secured and the expansion joints are aligned, we can connect the X and Y motor cables and mount the left-side cover.

Follow the instructions below:

• Connect the left motor cable (X motor) to the left connector on the xBuddy board. It is labeled X.

• Connect the right motor cable (Y motor) to the right connector on the xBuddy board. It is labeled Y.

• Make sure that the safety latches click in place. 

• Mount the left side panel back onto the printer. Secure it in place with 3 nylon rivets in the highlighted positions.

Once the left side cover is secured in place with three nylon rivets, we are finished with the CORE One GEN 2 guide.

Return to the Prusa INDX guide to step ELECTRONICS COVERS: PARTS PREPARATION  and follow the rest of the Prusa INDX guide to finish the conversion.