6 - Feed problem


Of course, we still have that problem.

The top pressure rollers are now too far back. If the printer reverses (as it does to activate the pump), these rollers fall off the feed roller and will not reengage.


So, to start with, we need to remove the pressure rollers. Remove each of the springs.


Now, at the front, free the catches holding the pressure roller support frames.


After removing the roller, it looks like this.


Put a cut off section of heatshrink tubing round the roller and shrink it. Be careful to use a size that can completely shrink onto the roller. Heat it until it is once again round and you can roll it on your desk.


The tubing I used. Initial diameter, 10mm. I used 2 layers.


Missing here are pictures showing the cutting down of the pressure roller supports.
All you need to do is trim a few mm from the rear edges of the supports that are now rubbing on your newly expanded rollers.

Now, reattach the roller supports. This is easier without the rollers attached.


Reinsert the rollers by lifting up the roller support (from the back is easiest) then placing the roller underneath and letting it snap into place.

You may notice that one of my rollers is not factory issue. Unfortunately, a bandsaw is not the most controllable option for cutting a small amount of plastic from these supports. A little bit of hotmelt glue and heatshrink solved this problem.

Also, the rollers as shown are larger than actually is able to fit under the head. This is why you can't expand them more than two or so layers. I removed these extra layers at a later stage.


Just in case you weren't sure, yes. This is a hack. Even with the above modifications, the roller supports still kept disengaging.

Pictured here is one solution, admittedly not so pretty. Measure and cut a length of hotmelt glue stick, long enough to hold the roller support when it is contacting the roller. On the nearside, attach something metal so the relatively soft glue stick will not stick to the roller support. Put a blob of hot hot melt glue on the other side and stick it carefully in position.

In this picture you can also see the extension to the paper sensor. Cut the wire, splice in a section of IDE / floppy / ... cable. It needs to be long enough to reach to the other side of the feed tray.


Fuzzy close up of one of the supports.


And another section done! Hacking time just flies by, doesn't it?
On to 7 - Feed tray