Saturn S cover rebuild with a flipping hood mechanism

Nov 02, 2026 Last reply: 1 hour ago 3 Replies
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The detail that caught me off guard here is the hood movement. The red UV-filtering acrylic hood lifts, gets pushed back, and then just hangs there, suspended open on its own. Then it can be pulled forward and down until it rests flush against the base. That is a far nicer motion than the usual lift-and-hope-it-stays routine, and the mechanism holding it open mid-swing is what makes the whole upgrade feel considered rather than improvised.



The build itself starts with the original cover. A custom back piece was designed to fit and work with it, and the cover was cut with a jigsaw running a fine saw blade for clean edges. Paper tape went over every cut line first, both to secure the edges and to mark the lines. The side holes for the axis screws were drilled with a 14mm diamond drilling crown cup. The finished sides come out really clean, which is not something I would expect from a jigsaw on a printer cover.



Not everything landed perfectly, and credit to the maker for saying so. Vibration during cutting left the back of the cover not perfectly straight, and the drilled holes are not perfect either. Apparently the design is forgiving enough that this does not matter, and the back piece works as intended anyway. Red and light blue 3D-printed brackets are mounted on the build, a nice bit of visible colour on an otherwise functional part of the machine.



The one open item is testing. The design needs more time in use before it gets published, so anyone hoping to copy this will have to wait a bit. I am curious what a longer testing period turns up.


Cutting the original cover with a jigsaw rather than replacing it seems like the smart call here. A fine blade plus tape over the lines is exactly how I would approach acrylic, and the clean sides back that up. The trade-off is vibration, which is why the back ended up not perfectly straight. A slower feed rate might have helped, though the forgiving design seems to absorb it.

How did the hood stay suspended in the open position? I assume the axis screws drilled with the 14mm crown cup are part of it, but I would love to know whether the brackets provide the resistance or if something else holds it there. Also curious how much slop those imperfect holes ended up allowing in the movement.

One idea: oversized washers over the drilled holes. If UV light is seeping through those side holes, wider washers would cover the imperfect edges and block it, and they would also hide the drill marks. Given the holes are not perfect and the design is meant to be published eventually, tidying them up that way before release could make the whole mechanism look sharper too.

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