Two Trees Sapphire Plus SP5 top hat

I built this because the printed top hats were too fragile and flimsy. With aluminum profiles, it's built like a tank. I'm writing this description in a hurry, make sure to open the drawing to check every features and dimensions, I may be missing something.

Complete Fusion drawings and STEP files are provided. The Fusion file is somewhat parametric, you can change some parameters such as top hat total height, acrylic thickness, screws size and other stuff to automatically adjust the drawing to your needs. I'm not a speed modeling champion or anything, just an old guy doing my things and sharing in it Printables, so make sure to double check the drawing after changing the parameters.

The default is set to a 150mm total height top hat that uses M4 screws, T-Nuts and brass inserts. Note that you'll need to drill two holes in the rear of your printer frame to attach the cable support, this is absolutely needed to end all cable issues while moving your print head.

The aluminum profiles are threaded for M5 screws and uses blind joints, you need some skill with miter saw and taps to cut and make threads in the aluminum profiles! You'll also need an acrylic cutting blade and a large metal ruler to cut the panels, I used dead LCD acrylic panel from junkyard and it was cheap af like $5 for each large panel (probably from 55" dead panels) enough to make a 250mm or taller top hat.

I provided 1mm and 2mm shims to put between the blind joints because sometimes you'll end up cutting the profiles too short because I measured once and cut twice :) so a few adjustments to make everything square was necessary.

The cable gland was taken from other project from Printables (https://www.printables.com/model/114283-cable-gland-all-sizes). The two part internal shim that holds the cable you'll have to make it yourself, it depends from your filament PTFE tube and umbilical cable. I use CAN bus, so it's very different from the default cable.

BOM

44x M4x10mm BHCS Screws

04x M4x12mm BHCS Screws

08x M5x25mm BHCS Screws

04x M5x10mm FHCS Screws (NOT countersunk)

46x M4 T-Nuts for 20x20 profiles

02x 458mm 20x20 Aluminum profile

02x 446mm 20x20 Aluminum profile

02x M4 x 4 x 4mm Knurled brass insert (can be longer, just adjust the drawing for yours).

02x *VAR* 20x20 Aluminum profile - this is a personal taste, I wouldn't recommend lower than 130mm for a direct drive setup, which gives a total of 150mm height). This is what I went for, but if I had to built it again, I would go for a little bit higher like 170mm for a total of 200mm height. This directly affects the costs because of the acrylic availability and prices (a higher tophat will obviously cost more).

01x 421.8 x 449.8 x 3mm acrylic top panel

02x 430.8 x *VAR* x 3mm acrylic side panels

02x 458.4 x  *VAR*  x 3mm acrylic front and rear panels - the panels are sized with a -0.5mm offset from the tab borders for a comfortable fit without wobbling. The tabs are sized with +0.4mm thickness so they won't press too hard against the acrylic to avoid warping or breaking. The default is 3mm acrylic thickness. With my 150mm total height top hat, the sides, front and rear panels has 140.4mm height.