Hot End - Heated Block

Materials:

1. 16mm x 45mm PTFE Rod
2. About 10cm PTFE tape
3. Kapton tape
4. M6 Brass Barrel (5cm / 4cm)
5. 0.5mm / 0.34mm Brass Nozzle
6. Heat Resistor
7. Thermistor
8. Aluminum Block

Tools:

1. 3mm drill bit
2. 5mm drill bit
3. M6 Tap
    

Steps:

1. Use 5.0mm drill bit to drill a 2cm/1.5cm deep centred hole in the PTFE rod (overlapping the original 1.75mm or 3.0mm central hole)(Figure 1, Figure 2).
2. Create a M6 insert by using M6 Tap (Figure 3, Figure 4).
3. Revolve the brass barrel into the the heat block(Figure 5), and then use PTFE tape to seal both ends of the brass barrel in order to prevent any leak, 2-3 wraps would do the work (Figure 6).
4. Connect the PTFE rod to brass barrel. Before you tight them with a clamp, you MUST make sure the path is smooth enough by using a 3mm/1.75mm plastic to go though it(Figure 7). Once again, the intersection is very important, the connection can not be loose nor too tight, too tight will not give you a smooth path.
5. Once you have a tight, smooth, and clean connection of PTFE rod and barrel, connect the nozzle to the barrel, then revolve the heat block and tightly attach to the nozzle(Figure 8). After this step, you should have everything holding together tightly, and should be able to see through the hole.
6. extend both heat resistor and NTC thermistor with wires (Figure 9), it would be better if you can solder them together for better connections(Figure 10).
7. tape around the heat resistor, and the thermistor by using kapton tape to prevent short circuit (aluminum block is conductive) (Figure 11).
8. place the heat resistor, and the thermistor into the heat block, and tape it around to make sure things stay in their position (Figure 12, Figure 13).

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