lid_thinbox_h = 9;
lid_fatbox_h = 24;
-lid_fatbox_switches_h = 6+2;
+lid_fatbox_switches_h = 6+4;
lid_max_switches_w = 70;
lid_switches_y_slop = 3;
total_len = 260;
thinbox_len = 87;
+rail_overlap = 8;
+
lid_top_wall = 1.5;
lid_front_wall = 1.5;
lid_side_wall = 1.5;
peg_top_thick = 1;
peg_straight_len = 3;
-peg_inner_slop = 0.2;
-peg_outer_slop = 0.1;
+$peg_inner_slop = 0.75;
+$peg_outer_slop = -0.9;
+$peg_outer_slop_engage = 0.1;
peg_slope = 1;
lid_side_slop = 0.5;
+lid_rail_behindslop = 0.5;
+lid_rail_strongwall = 2.5;
// computed
lid_inner_kink = [thinbox_len, thinbox_len*2];
-lid_inner_w = patbox_side + lid_side_slop * 2;
+lid_inner_w_nom = patbox_side;
+lid_inner_w = lid_inner_w_nom + lid_side_slop * 2;
lid_seatline_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop;
lid_seatline_h = lid_fatbox_switches_h;
-echo(lid_seatline_w);
-
peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope;
-echo(peg_main_height);
+thinbox_front_z = lid_fatbox_switches_h + lid_fatbox_h - lid_thinbox_h;
+
+raillen = patbox_side/2 + rail_overlap;
module LidSideProfile(){
polygon([[-lid_top_wall, lid_inner_max_h],
- [lid_inner_kink[0], lid_inner_max_h],
- [lid_inner_kink[1], lid_inner_min_h],
+ [min(lid_inner_kink[0],total_len), lid_inner_max_h],
+ [min(lid_inner_kink[1],total_len), lid_inner_min_h],
[total_len, lid_inner_min_h],
[total_len, -lid_front_wall],
[-lid_top_wall, -lid_front_wall]]);
}
+module RailProfile(lslop=0.1){
+ yt_base = thinbox_front_z;
+ yt = yt_base - lid_rail_behindslop;
+ pegx = (lid_inner_w_nom - patbox_centres)/2;
+ sw = lid_rail_strongwall;
+
+ polygon([[-lslop, yt],
+ [pegx - peg_main_dia/2, yt],
+ [pegx - peg_main_dia/2, yt_base - peg_straight_len],
+ [sw,
+ yt_base - peg_straight_len - (pegx - peg_main_dia/2)/peg_slope
+ +sw],
+ [sw,
+ lid_seatline_h - 1],
+ [-lslop,
+ lid_seatline_h - 1]]);
+}
+
module LidSide(){
overlap = [0.1, 0.1, 0.1];
// lid top
translate([-lid_top_wall, -lid_side_wall, -lid_front_wall])
cube([lid_top_wall, lid_inner_w/2 + 10, lid_front_wall + lid_inner_max_h]);
+
+ // rail
+ rotate([90,0,90])
+ translate([0,0,-0.1])
+ linear_extrude(height=raillen+0.1) //todo
+ RailProfile();
+
+ // rail end
+ translate([raillen, 0,0])
+ intersection(){
+ rotate_extrude($fn=50)
+ RailProfile(lslop=0);
+ translate([0, 25-0.1, 0])
+ cube(50, center=true);
+ }
+}
+
+module Lid(){ ////toplevel
+ for (m=[0,1])
+ mirror([0,m,0])
+ translate([0, -lid_inner_w/2, 0]) LidSide();
}
module PegProfile(){
- polygon([[-peg_engage_depth, (peg_engage_dia - peg_outer_slop)/2],
- [0, (peg_engage_dia - peg_outer_slop)/2],
- [0, (peg_main_dia - peg_outer_slop)/2],
- [peg_straight_len, (peg_main_dia - peg_outer_slop)/2],
- [peg_main_height, (peg_max_dia - peg_outer_slop)/2],
- [peg_main_height+peg_top_thick, (peg_max_dia - peg_outer_slop)/2],
- [peg_main_height+peg_top_thick, (peg_inner_dia + peg_inner_slop)/2],
- [-peg_engage_depth, (peg_inner_dia + peg_inner_slop)/2]]);
+ polygon([[-peg_engage_depth, (peg_engage_dia - $peg_outer_slop_engage)/2],
+ [0, (peg_engage_dia - $peg_outer_slop_engage)/2],
+ [0, (peg_main_dia - $peg_outer_slop)/2],
+ [peg_straight_len, (peg_main_dia - $peg_outer_slop)/2],
+ [peg_main_height, (peg_max_dia - $peg_outer_slop)/2],
+ [peg_main_height+peg_top_thick, (peg_max_dia - $peg_outer_slop)/2],
+ [peg_main_height+peg_top_thick, (peg_inner_dia + $peg_inner_slop)/2],
+ [-peg_engage_depth, (peg_inner_dia + $peg_inner_slop)/2]]);
}
-module Peg(){
+module Peg(){ ////toplevel
+ echo($peg_outer_slop_engage);
rotate_extrude($fn=50)
rotate([0,0,-90])
PegProfile();
}
+module Pegs(){ ////toplevel
+ baseslop = 0.1;
+ dslops = [0, -0.5, -1.0, -1.5];
+ stride = peg_max_dia + 4;
+ for (i=[0:len(dslops)-1]) {
+ translate([i*stride,0,0])
+ assign($peg_outer_slop_engage= baseslop + dslops[i])
+ Peg();
+ }
+}
+
module AtFixingCentres(){
for (fc=[-1,+1]) {
translate([patbox_side/2 + fc*patbox_centres/2,
}
module Demo(){
- translate([0, -lid_inner_w/2, 0]) LidSide();
- translate([0,0, lid_fatbox_h])
+ Lid();
+ translate([0,0, thinbox_front_z])
rotate([0,180,0]) translate([0, -patbox_side/2, 0])
rotate([0,0,90]) union(){
%TopPattressBox();
//LidSide();
//PegProfile();
//Peg();
+//Pegs();
//TopPattressBox();
-Demo();
+//RailProfile();
+//Demo();
+//Lid();
+//translate([0,0,-lid_fatbox_switches_h]) Lid();