E3NS - Ender 3 V2 Neo Hotend using Ender 5 S1 Parts

Note: This is considered a beta version right now, as I have not installed my printed parts yet E3NS This is a hotend designed for Ender 3 Neo/V2 Neo printers using the Ender 5 S1 hotend, extruder, fans and PCB. My goal was to up the printing temperature capabilities of my 3 V2 Neo and add direct drive. I happened to have an ongoing project 5 S1 that I wasn't going to be using any hotend components from, so I decided to use that as my base. All parts are intended to bolt up to the original Neo X carriage. I drew some of my styling queues from the MK4S blower design, so I tried to come up with a name that somewhat pays respect to that. Hence, the E3NS (Ender 3 Neo S1/Sprite) was born. That being said, I believe that the 5 S1 extruder is just the same as the Sprite Extruder SE, so it's very possible to use this design without an Ender 5 S1 donor. Using the S1 hotend PCB is very optional, as it really just exists to simplify the wiring. If there are other PCB out there that work with the sprite extruder, I'm happy to take a crack at making other versions of the enclosure for them. I also included an extra set of blower brackets that lift the 5015 blower so that the original Neo hotend may be used. Again, happy to take a look at fitment for additional hotends that people may want to use with this design. Hardware Requirements I was able to pull all of the needed screws from my donor E5S1 printhead. However if you are building this a-la-carte, here are the screws and heat sets needed: M3x5x4 Heatset Thread Inserts, qty = 12 M3x6mm Screws (PCB Mount, Blower Rear Cover, Carriage), qty = 5 M3x8mm Screws (Blower Cover), qty = 7 M3x16mm Screws (PCB Connector), qty = 2 M3x30mm Screws (Extruder Mount), qty = 2 M3 Mounting Screws for Hotend, qty = 2 1X 4010 Fan 1X 5015 Blower Note: Some items may vary depending on your actual setup Assembly Assembly should be fairly straight-forward if you've tinkered with your printer before. But below are some brief steps: Remove existing shroud, fans, hotend etc. from your x carriage. Keep your CR touch spacer in place. Slide the Extruder Mount over the carriage and secure from the rear using an M3x6mm screw Mount your hotend to the front of the Extruder Mount. If using the 4010 Fan spacer, place this over the hotend. Secure to the carriage with your mounting bolts. This design uses a short piece of PTFE/bowden tubing to bridge the gap between the extruder and the hotend, just like the 5 S1. You will need to measure and cut this piece to fit your setup. Once done, you should be able to mount the extruder with the M3x30mm screws from the rear of the mount. Next up mount hotend fan. The 4010 can either mount directly to the 5 S1 hotend, or you can use the 4010 spacer I designed. Now assemble the blow housing. Slide the 5015 blower into place. Then the duct should be able to tilt into place by aligning the tabs with the housing. Then secure the duct with a single M3x8mm screw. Route the blower wiring around the blower in the provided slot then place the rear cover over top and secure with a M3x6mm screw. Then install your blower brackets on the left and right sides of the mount and slide the blower housing in between them. This step should use the remaining 6 M3x8mm screws. If using the 5S1 hotend, sandwich the CR Touch Spacer between the sensor and the metal bracket. If using the PCB, first mount it to the rear PCB housing with a single M3x6mm screw. Then use the two M3x16mm screws to connect the front PCB housing. The PCB housing mounts to the extruder using 2 M3x6mm screws. Connect all your wiring and you should be good to go. I'm using the sprite extruder ribbon cable made for Ender 3/V2/Neo and the pinout seems to work. You will need to calibrate the extruder, refer to Sprite Extruder documentation for this. Notes: Lastly, I just want to point out again that this is still something I would consider as a beta/prototype design. I have printed all the parts and assembled the hotend, however I have not yet installed it on my personal printer yet as I'm trying to get through some other prints before disassembly. Once I've got it up and running, I'll consider it verified and final. I will try to keep this page updated with any changes and monitor the comments for any suggestions or requests.