Falcon 2, Frame out of alignment

@Booster First of all, I don’t have this issue, so it’s only a suggestions, not some fix that I did try myself.

…this being said…
Be gentle - take care not to force anything. Screws shouldn’t be too tight - when tightening a screw, hold the allen key by the short side. If you use the long side, you’ll have too much “power”…

Standing in front of the Falcon 2:
A. From right to left, just behind the front of the machine, there’s a rod with 2 cogwheels at each end through which the belts pass on each side - it’s this rod, with the motor in the middle, that manages the laser’s back/forth movement.
B. On each side of the device, you’ll see an oval hole with a screw in it - this is the screw to secure the tensioner and prevent it from moving once adjusted.
C. At the rear of the unit, there are 3 screws (vertically) on each side. The top 2 are for securing the frame - the bottom one is for the tensioner.

First of all, I’d check if the frame itself is square. Use a carpenter square or something similar that you are sure is square and check all corners. Or you could have the laser cut a piece of thin wood like the one that came with the device - that should create a proper square piece even if not parallel to the front :smiley:
Alternatively, you could mesure the distance between the front-left + back-right corners, and do the same with the front-right + back-left corners - your 2 measurement should be identical!

If the frame isn’t square:

  1. Release the 2 frame screws on each side on the back (See C above)
  2. Try to gently move the frame to be square and tighten back one screws from each side, but don’t tighten too much yet.
  3. Play with the other screws and move the frame if necessary to try to get as square as possible.
  4. Once satisfied that your frame is really square, tighten the screws trying to keep the frame as is - try not to screw all this hard work :slight_smile:
  5. Once all is screws are tightened up properly, check the frame for squareness - repeat steps above if necessary…

If/when the frame is square and you still face the non-paralelism of the arm and front of the unit, here’s what I’d suggest :

  1. Choose one of the sides to work on - you shouldn’t need to do it on both sides.
  2. Loosen the screw securing the tensioner (see B above)
  3. Using the bottom screw at the rear of the unit (see C above), release the tensioner enough to allow you to “jump” one or more teeth on the gear (see A above) and move the laser arm parallel to the front of the unit.
  4. Once you’re happy with the alignment, apply tension with the bottom screw at the back - try to give the belt the same tension as the belt on the other side of the unit.
  5. Re-tighten the side screw (B) to secure the tensioner and prevent it from moving.

Let us know if it works.

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