For the TS model, there are assembly videos now on youtube: Wilson TS Assembly series (6 videos)
The assembly instructions are maintained officially at the github repository along with the design files themselves. The instructions below are duplicated from there. In the docs/images folder of the repository you will also find assembly photos that correspond to each step (numbered). Also, for the extruder assembly you should cross-reference the Prusa i3 Rework extruder assembly article, because it is the same extruder. Note: these are the instructions for the Wilson RS.
1. Assemble the Y axis (part 1) 1.1 Gather the following parts a. The two M10 threaded rods b. The Y axis smooth rods c. The plastic Y end pieces (2) d. The two plastic frame brace supports e. 12 M10 nuts and washers f. Four linear bearings (LM8UU) 1.2 Hardware Assembly * Slide a brace support onto each threaded rod. On each side of the supports, put a washer, a nut, another nut and another washer (in that order). * Next, slide two two Y end pieces over the ends of the threaded rods. Place a washer then nut on each end. 1.3 Tightening the Y axis * Start at one end (either Y motor or Y idler end) and tighten the two nuts against the end so that the threaded rod is flush with the outside of the nut. Tighten both sides of the first end while everything else is loose along the threaded rods. Use two wrenches to tighten the nuts against the end until snug (tight, but don't compress enough to deform or break the plastic). * Place two linear bearings on each Y axis smooth rod. * Next, with the other Y end still loosely attached, place the two Y axis smooth rods across the top and fit into the grooves along the top of the ends. * Press down on the corners (not in the middle of the rods!) to seat the rods into the Y ends. * Tighten one corner of the remaining end. * Now take a moment to measure with a ruler between the end posts of the tightened side. (355mm for reference). * Flip the assembly around and repeat the measurement as you tighten the remaining corner (tighten it just a little first, then measure. If the distance is a little less than the first side, tighten the inner nut outward toward the outer nut, if the distance is a little more than the first side, then tighten the outer nut toward the inner one. Try to get the two sides as close to the same distance as possible. This will help ensure your y axis bearings don't experience any binding forces). * Repeat the measurement on the first side and check that all corners are nice and snug. Take your time on this step, it may require a couple iterations to get the axis square. 1.4 Prep the Print Bed While the Y axis assembly is free, it is a good time to prepare the print bed which you will attach later. Gather the following materials a. The Y axis assembly you just completed b. The wood print bed support c. The heat bed d. The four linear bearing holders e. Eight miniature zip ties * Place the heat bed circuitboard over the wood bed and mark the four corner locations with a pencil. * Put the heat bed circuitboard aside and place the four linear bearing holders over the linear bearings along the Y axis rods. * Turn the Y axis assembly over so that the smooth rods (and bearing holders) are against the wood print bed surface. * Align the front edge of the two bearing holders nearest the Y end idler with a line that is 80mm from the front edge of the bed. * Align the back edge of the two bearing holders nearest the Y end motor mount with a line that is approx 10mm from the back edge of the bed. * Mark all the holes for the bearing holders with a pencil. * Remove the wood print bed and drill all the holes you marked with a 5mm drill bit. (You want the holes a little over-sized so that there is some room for the screws to "float" when you attach the bed). * Attach the linear bearing holders to the Y axis linear bearings with zip ties. Set the prepared wood print bed aside. 2. Assemble the Frame (part 1) 2.1 Gather the following parts a. The two side pieces of 2020 aluminum extrusion (the longer ones, generally) b. One of the two horizontal pieces of 2020 aluminum extrusion (the shorter ones, generally) c. 22 T-slot nuts d. 14 M5 x 8mm screws e. The plastic Z motor holders (2) f. The plastic rear frame brackets (2) 2.2 Hardware Assembly * Slide 6 T-nuts into one side of the shorter extrusion (this wlll be the bottom piece of the frame). * Turn the extrusion over (being careful not to let the nuts slide out that you just put in) and slide 8 more nuts into the opposite side that you begain with. * Place the two remaining extrusions to the sides of the first, and slide two T nuts into each on the side facing up. * Get the two corner braces and place one over each corner. Line up the two nuts on each extrusion and attach the braces with a total of 8 M5 screws. Note that the longer extrusions (the "sides" of the frame) should cover the ends of the bottom extrusion piece. Leave the screws loose until all 8 are started. * Stand the frame "upright" to ensure the sides are slid down flush with the bottom and alternately tighten until all the screws are tight. * Rotate the frame so the other side is facing you and put it back flat on your work surface. * Slide two more T nuts into each side piece and attach the motor mounts the same way you did the rear brackets, using 6 more M5 screws. * You should have four T nuts sliding around between the lower corners, which will be used to attach the Y axis to the frame in the next step. 3. Mount the Y axis to the frame 3.1 The following parts are used during this step: a. The partially-assembled Y axis from step 1. b. The partially assembled frame from step 2. c. Eight M5 x 8mm screws 3.2 Mounting the Y axis * Place the Y axis over the frame so that the Y motor end is toward the rear, and the Z motor brackets are toward the front. * Slide the Y axis along the threaded rods so that there is ** 135mm ** from the Y motor end and the frame braces * Tighten the nuts on the first side finger-tight against the frame brace then turn the assembly around and repeat on the other side. Measure a couple times to make sure the distance from the y motor end to the frame braces is the same on each corner. Next slide the Y axis assembly left or right along the lower frame extrusion so that there is ** 50mm ** from the upright extrusion to the inner edge of the frame brace on the "left" side of the printer (as viewed with the Y axis idler toward you). * Tighten the frame braces using 8 M5 screws into the T slot nuts that are alread in the lower frame extrusion. Finish tightening the nuts of the threaded rod against the braces, double-checking that the distance from the Y end to the braces is the same on each side. A convenient place to measure this after the nuts are snug is from the inside of the nuts (approx 116mm). 4. Assemble the X axis (part 1) 4.1 Gather the following parts: a. The two plastic X end pieces ("motor" and "idler") b. Eight linear bearings (LM8UU) c. The two X axis smooth rods d. Two M5 nuts 4.2 Hardware Assembly * Press two linear bearings into each X end. * Using pliers, gently press an M5 nut into the provided insert in each end. * Place two linear bearings on each of the smooth rods. * Press each X end onto the pair of smooth rods, being sure to orient them so that the M5 nuts are on the same side of the rods. 5. Assembling the frame (part 2) 5.1 Gather the following: a. The two upper Z axis mounts. b. The remaining piece of aluminum extrusion (the top bar) c. Four t-slot nuts d. Five more t-slot nuts if you are going to use the filament holder and SMART electronics mount. e. Four M5 x 8mm screws 5.2 Assembly * Insert two t-slot nuts into the top side of the aluminum extrusion. * If you will be using the filament holder, rotate the extrusion 90 degrees and insert two more t-slot nuts into the top side. * Insert the remaining t-slot nuts into the side opposite from the one you started with. * Attach the upper Z axis mounts to the ends of the extrusion, tightening the M5 nuts just until snug. Be sure to keep the two t slot nuts for the filament holder on the "top" and the t slot nuts for the SMART electronics mount and filament holder to the back (side away from the rod holders). 6. Mounting the X axis to the Z axis 6.1 Gather the following a. The partialy assembled frame from step 3. b. The X axis assembly from step 4. c. The upper frame assembly from step 5. d. The remaining two smooth rods e. The Z axis threaded rods (M5) f. Two NEMA17 stepper motors g. Eight M3 x 10mm screws (washers recommended) h. Two Z axis couplers (either 5mm x 5mm couplers or 3/16" vinyl tubing) i. Eight t-slot nuts j. Eight M5 x 8mm screws 6.2 Mounting the X axis onto the frame. * Attach the two Z axis motors to the motor mounts using four M3 x 10mm screws each. Place the z axis couplers on each motor shaft. * Press each Z axis smooth rod firmly down into the rod holder of each motor mount, being careful to keep the rods straight up and down to avoid breaking the mounts. * Gently slide the X axis assembly down over the Z axis rods. If the linear bearings in each X end do not align with the Z axis rods, remove the X axis assembly and gently push/pull the two ends to get the distance right. The motor end of the X axis assembly should be on your left (with the Y idler end toward you). * Insert two t-slot nuts into both the front and back sides of each end (8 total). You may want to hold the frame assembly on your lap with the upright extensions horizontally at the point, so that the t slot nuts don't slide down to the botttom of the frame. If they do, simply place your hands over the tops of the extrusions, keeping the z axis smooth rods supported, and tip the assembly over to slide the nuts back toward the top. * Place the upper frame assembly on the frame. Fit the tops of the z axis smooth rods into the rod holders. * Secure the top of the frame using 8 M5 x 8mm screws. Be sure to press the top of the frame down securely onto the vertical extrusions, and then press inward on each top corner to seat the upper extrusion against the sides. * With the X axis assembly resting at the bottom of the Z axis smooth rods, thread the z axis threaded rods down through the nut in each X end until the threaded rods rest against the Z axis motor shafts. * Tighten the z axis couplers. 7. Completing the Frame Assembly 7.1 Mount X and Y motors * In addition to the frame from the previous step, gather the following: a. Two NEMA17 stepper motors b. Two belt pulleys c. The two idler bearings and plastic bearing guides d. Three M3 x 10mm screws e. Three M3 x 14mm screws f. Two M4 x 20mm screws and nuts * Mount the motors to the X and Y axis motor mounts using three screws each. * Fit a pulley on each motor shaft and tighten the grub screws to keep them secure. * Snap an idler bearing into each pair of plastic bearing guides, then attach the idlers to the opposite ends of the X and Y axis from where you attached the motors. Don't overtighten the screws that hold on the idlers. 7.2 Attach print bed * You will need: a. The print bed you prepared earlier. b. Eight M3 x 14mm screws and an equal number of M3 nuts and washers. * Mount the print bed to the Y axis bearing holders. The washer should go on the screw first, which should go downward through the wood print bed and bearing holder, and secured with a nut. Attach each screw only loosely first, then check that the bed slides smoothly back and forth along the Y axis. Tighten the nuts a little at a time until secure. 7.3 Attach the X carriage. * You will need: a. The printed X carriage b. Eight miniature zip ties * Attach the X carriage with the belt guide "up" and with the flat surface (where you will attach the extruder) toward the front of the printer (the Y idler end). 7.4 Attach Belts * You will need: a. The X axis drive belt b. The Y axis drive belt c. The Y belt holder d. 8 Miniature zip ties * Thread the X axis belt into place and secure with four zip ties (two on each side of the extruder, trimmed short after tight). * Turn the printer over or have a friend hold it upside down, being careful not to lift by or put pressure on the X axis rods. * Thread the Y axis belt into place. Hold the belt tight and use as a guide for placing the Y belt holder. The leading edge of the belt holder should be approximately in the middle of the wood print bed. * Mark the holes for the Y belt holder, then set the holder and belt aside and drill the two holes with a 4-5mm hand drill. * Attach the Y belt holder with the head of the screws to the bottom, with a washer and nut on the wood side. 7.5 Attach accessory mounts * You will need: a. Filament holder mounts b. SMART display mounts c. RAMPS electronics frame mount c. Eight M5 x 8mm screws 7.6 Attach heat bed * You will need: a. The heat bed circuitboard b. Four M3 x 30mm screws and locknuts c. Four springs (approx 1" long uncompressed) * This is a good time to attach the heat bed thermistor if you have not already done so. Depending on your heat bed and thermistor, the most likely procedure here is to secure the thermistor to the middle of the bottom-side of the heat bed with a strip of Kapton tape. * Attach the heat bed with a screw through each corner, with the head of the screw up, down through the heat bed, through a spring, then through the wood print bed, and into a lock nut. Compress the springs about halfway (you will adjust each corner later to level the bed more precisely). 7.7 Attach Limit Switches * You will need: a. Three micro limit switches b. The Z axis limit switch mount c. One T-slot nut and M5 x 8mm screw c. M2 x 16mm screws and nuts as needed (up to 6 each) * If your limit switches do not already have wires attached, do that now. You will need approximately 45cm (18") of wire on each switch (depending on where you locate the electronics). * Slide a T nut into the outer side of the left upright piece from the bottom. Attach the Z endstop holder with a M5 x 8 screw. 8. Extruder Assembly and Mounting 8.1 Assemble the Extruder * You will need: a. The extruder body and idler. b. The hot end. c. The M8 Hobbed bolt d. Two M8 nuts (or one M8 locknut), and washers (probably 4). e. Two springs (approx 1" long uncompressed) f. The M8 x 20mm smooth rod (or M8 x 20mm grub screw) g. Three 608 bearings h. Two M3 x 60mm screws i. The larger extruder gear. j. Three M3 x 30mm screws k. Five M3 nuts * If your hot end was not previously assembled (heater resistor and thermistor), do that now. Follow the instructions for your particular hot end. * Slide the M8 x 20mm shaft through a 608 ball bearing then push this assembly inside the extruder idler. You may have to use pliers to snap the shaft into place. Apply even pressure on top of the shaft/bearing to avoid cracking the plastic idler. * Insert an M3 nut into the inner recess provided on the idler. Use pliers or a hot iron to fix the nut into place (be careful not to break the idler in the process). * Thread an M3 x 30mm screw through the outer side of the idler on the side you just inserted the nut, just until the screw starts into the nut. * Fix the idler assembly to the Wade Body Extruder and then finish screwing the M3 x 30 bolt all the way through the fulcrum support. * Slide the Wade Big Gear through the hobbed bolt so that the hex head of the bolt is secured in the recess of the big gear. Slide 3-5 M8 washers onto the bolt (they go between the gear and the body of the extruder to provide spacing) followed by one 608 bearing. Insert the bolt into the extruder body, securing the bearing in the hole provided. Add another 608 bearing on the loose end of the bolt, followed by another M8 washer and locknut. Tighten the lock nut just enough to keep the hobbed bolt in place; it should spin freely. * Insert two M3 nuts in their slots on the top of the extruder body. Place an washer, then spring, then another washer on each M3 x 60mm screw, then thread the screws through the slots of the idler and into the nuts you inserted in the extruder body. Tighten the screws until the springs are well compressed (this keeps tension on the printer filament). If either spring is too short (or the bolts are too long) to compress properly, remove the bolt and place an M3 nut on first (before the washer/springs). * Insert the hot end into the 16mm hold on the bottom of the extruder. * Secure the hot end to the extruder body by threading in two M3 x 30mm screws through the front of the extruder (they will pinch the sides of the hot end on their way through the plastic body). Secure with M3 nuts and tighten well (it is critical that the hot end be rigid and not wobbly). 8.2 Connecting extruder to X-axis * You will need: a. Extruder assembly b. Wade Small Gear c. One NEMA 17 motor d. The plastic fan duct. e. One 40mm x 40mm x 10mm fan. f. Four M4 x 25 mm screws g. Four M4 nuts h. One M3 x 30mm screw i. Seven M3 x 14mm screws j. Three M3 washers k. One M3 x 8mm screw l. Five M3 nuts m. One M3 locknut * Insert two M4 nuts in the bottom of the extruder body in the slots provided. Use pliers to gently press the nuts into the plastic, or press them in with the tip of a hot soldering iron if the holes are too tight. * Insert two M4 nuts into the slots on the sides of the extruder body. * The extruder is held to the X carriage by the four M4 x 25mm screws. Insert the four screws through the back of the X carriage and then slide on the extruder assembly (thread the top two screws into the nuts you just inserted). Then screw the two lower M4 nuts into place and tighten all four screws. * Insert an M3 nut into the slot on the small gear. Use pliers or a hot iron to press into place if necessary. * Slide the small gear onto the shaft of the NEMA 17 motor. If necessary, drill out the shaft hole on the small gear with a 5mm drill bit. * Insert the M3 x 8mm screw and tighten against the shaft of the motor. * Place the motor assembly against the Wade Extruder Body (supply wires upwards). Insert three M3x14 mm screws and three Ø3 mm washers without tightening. Slide the motor assembly against the Wade Big Gear and tighten the screws to hold the motor secure. * Attach the 40mm fan to the fan duct using four M3 x 14mm screws and M3 nuts. Make sure the fan is oriented so that airflow is going toward the duct (usually this means the side of the fan with a label on it will be against the fan duct). * Fix the Fan Duct assembly on the Wade Extruder Body with an M3 30mm screw and an M3 lock nut. Do not overtighten. 8.3 Install glass bed * Now is a good time to install the glass bed. Place the glass on top of the heat bed and secure with four paper-binder clips. If the X axis is too low, you may have to manually turn the two Z axis rods to lift it high enough so that the glass will fit underneat the hot end nozzle. 9. Connect the Electronics * You will need: a. The electronics controller of your choice (e.g. RAMPS) b. The power supply c. SMART display (optional) * Use the checklist below as you connect the electronics. If your electronics board has multiple options for connecting devices, make a note of which connection you use so that you can input the settings to your firmware. [ ] X axis stepper motor [ ] Y axis stepper motor [ ] Z axis stepper motors (2) [ ] Extruder stepper motor [ ] X axis limit switch [ ] Y axis limit switch [ ] Z axis limit switch [ ] Heat bed power [ ] Extruder heater power [ ] Extruder fan power