Mystery with Profile Bar on My Early XL — 6-Hole Version?
Hi all,
I recently purchased a used Prusa XL and have run into quite a mystery. First, let me say this printer is fantastic, and I got a great deal on it. It was manufactured in 2023 and had about 43 days of printing time when I purchased it.
Recently, I decided to upgrade the toolhead from single to dual. While mounting the docks, I ran into the step involving the profile bar — the small aluminum bar in the back channel that has threaded holes where the docks attach.
Here’s the issue: things were not matching up at all. After two separate chats with Prusa support, I learned that my profile bar is different from the documented version.
My bar has 6 tapped holes instead of 5 It is longer than the bar shown in the official documentation The holes are spaced at about 75 mm apart, whereas Prusa support says the spacing should be around 82 mm
Because of this, mounting two docks next to each other won’t work — the second head crashes into the first dock.
The mystery: Prusa support tells me that, even though my printer is an early XL, the bar should have been the same, and to their knowledge, no changes were made in production. So how do I have a bar with 6 holes that is longer and differently spaced?
Replacing the bar is not trivial — it requires an involved disassembly — so it’s not like someone just swapped in a random part. I initially wondered if maybe earlier XLs had closer holes or smaller docks, but support assures me this is not the case.
In the meantime, I have the “proper” bar coming and will go through the disassembly to replace it.
Any thoughts, theories, or experiences with odd profile bars on early XLs would be greatly appreciated. I would be curious if anyone else out there has a 6 hole version of this bar.
Thanks!
RE: Mystery with Profile Bar on My Early XL — 6-Hole Version?
Hi,
I think that part came semi assembled. So, maybe its from prusa themself an Error.
But, it could also be that the preowner changed that part by unknown reason? Selfbuild Index maybe?
RE: Mystery with Profile Bar on My Early XL — 6-Hole Version?
Maybe you can use the next holes for the Docking Station. I dont know If the Docking calibration would allow that.
Its Something you could try but be aware that it could fail catastrophic!
Better wait for spare parts
RE: Mystery with Profile Bar on My Early XL — 6-Hole Version?
I thought this could be the case too but its a 92 step process to dissemble this printer to get to that profile bar. Why would someone in their right mind want to swap it out, and its been a single tool unit up till now. It could happen but thats a lot of work to do.
RE: Mystery with Profile Bar on My Early XL — 6-Hole Version?
If I use the next holes I get a dock out of bounds error. The holes on my profile bar are closer together than the one support says should be in there. I was able to slide the bar all the way to the right and use the second hole for the #1 Toolhead dock and I could get it to calibrate. The next hole over is too close so I measured about 82mm from the first hole that works, then carefully drilled and tapped another hole in the profile bar as it sits in the printer. I was able to mount the second dock and got it calibrated. I was up and printing today and works. When I get the new profile bar I will eventually swap it out because some day Ill upgrade to 5 toolheads and this current 6 hole bar will not work.