poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 // Print, for each end:
   4 //
   5 //   CoverPrint
   6 //   StrapMount
   7 //   CatchAssembly
   8
   9 include <funcs.scad>
  10 include <utils.scad>
  11
  12 coarse = false;
  13 enable_head_cups = false;
  14
  15 main_dia = 71.2 + 0.50 - 2.26;
  16 top_thick_middle = 4;
  17 top_thick_by_oring = 3.0;
  18 top_middle_dr = 11;
  19
  20 main_cnr = 6.0;
  21
  22 min_wall = 3;
  23
  24 rivet_posn = 6.0 + 0.30;
  25 rivet_thick = 1.67;
  26 rivet_width = 4.15 + 1.0;
  27 rivet_tall = 5.51 + 1.49;
  28
  29 over_rivet_wall = 1.0;
  30 side_rivet_gap = 1.5;
  31 inside_rivet_gap = 1.5;
  32
  33 bayo_interf = 0.30;
  34 bayo_behind = 8.5;
  35 bayo_interf_width = 2.0;
  36 bayo_interf_slope = 0.5;
  37
  38 oring_thick = 5.0;
  39 oring_bore = 62.0;
  40
  41 oring_upper_embed_angle = 80;
  42 oring_compress = 0.1; // proportion
  43 oring_compress_more = 0.2;
  44
  45 oring_rm_beside = 8;
  46 oring_rm_scale = 2.0;
  47 oring_rm_angle = 20;
  48
  49 side_taper = 1.0;
  50
  51 bayo_gap = 6.0;
  52
  53 bayo_entry = 1.167;
  54 bayo_inramp = 0.9;
  55
  56 bayo_slice_size = coarse ? 5 : 1;
  57
  58 brace_hole_width = 1.0;
  59 brace_above_below = 1.2;
  60 brace_end_shorter = 0.3;
  61
  62 jig_thick = 1.4;
  63 jig_hole_dia = 3.0;
  64 jig_rim = 5;
  65 jig_mark = 5;
  66
  67 strap_loop_thick = 6;
  68 strap_loop_inside = 10;
  69 strap_loop_strlen = 10;
  70 strap_loop_elevation = 45;
  71
  72 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
  73 sm_main_thick = 2.0;
  74 sm_main_width = 20;
  75
  76 sm_bolt_dia = 3.5 + 0.1;
  77 sm_bolt_shaft = 21.0;
  78 sm_bolt_head_dia = 6.94 + 1.0;
  79 sm_bolt_head_thick = 2.14;
  80 sm_bolt_nut_width = 5.89 + 0.25;
  81 sm_bolt_nut_thick = 3.68;
  82 sm_bolt_tighten_allow = 2.0;
  83
  84 sm_bolt_y_clear = 0.75;
  85 sm_bolt_y_over = 0.5;
  86
  87 sm_closure_cnr = 3.0;
  88
  89 wm_thick = 5;
  90 wm_screw_dia = 4.5; // XXX
  91 wm_screwdriver_dia = 6.0; // XXX
  92 wm_screw_around = 4.0; // XXX
  93 wm_screw_slot = 3.5;
  94 wm_screw_head = 7.5; // XXX
  95
  96 wmb_screw_dia = 5;
  97 wmb_screw_around_x = 4; // XXX
  98 wmb_screw_around_y = 6; // XXX
  99 wmb_screw_depth = 10; // XXX
 100 wmb_nut_across = 8; // XXX
 101 wmb_gap = 1.0;
 102
 103 catch_stalk_h = 4.5;
 104 catch_stalk_len = 50;
 105 catch_tip_th = 4;
 106 catch_head_th = 3;
 107
 108 catch_pin_slop = 0.25; // each side, and above
 109 catch_pin_slop_x_extra = 0.0; // only on one side
 110 catch_stalk_above_gap = 1.5;
 111 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 112
 113 catch_strap_width = 12;
 114 catch_stalk_base_width = 15;
 115
 116 catch_knob_dia = 6;
 117 catch_knob_above_gap = 5;
 118 catch_knob_height = 3.0;
 119
 120 catch_stalk_below_gap = 1.0;
 121 catch_stalk_beside_gap = 2.0;
 122
 123 // calculated
 124
 125 TAU = PI*2;
 126
 127 bayo_entry_x = bayo_entry;
 128 bayo_entry_z = bayo_entry;
 129 bayo_inramp_x = bayo_inramp;
 130 bayo_inramp_z = bayo_inramp;
 131
 132 oring_mid_dia = oring_bore + oring_thick;
 133 oring_outer_dia = oring_mid_dia + oring_thick;
 134
 135 oring_oblate = (1 - oring_compress);
 136
 137 oring_y_rad = oring_thick/2 * oring_oblate;
 138 oring_x_rad = oring_thick/2 / oring_oblate;
 139
 140 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 141
 142 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 143 side_thick = rivet_tall + over_rivet_wall;
 144
 145 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 146
 147 middle_bot_z = top_z - top_thick_middle;
 148
 149 bayo_top_z = bayo_behind + bayo_gap;
 150
 151 bayo_nom_rad = main_dia/2 + side_thick;
 152 bayo_real_rad = main_dia/2 + rivet_tall;
 153
 154 rivet_entry_width = rivet_width + side_rivet_gap;
 155
 156 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 157
 158 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 159 handling_angle = 45;
 160
 161 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 162 sm_outer_rad = sm_inner_rad + sm_main_thick;
 163
 164 wm_main_width = sm_main_width;
 165 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 166                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 167 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 168 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 169 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
 170 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 171 wm_y_slot1_max = wm_y_max + wm_screw_slot;
 172 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 173 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 174 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
 175 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 176
 177 wmb_mount_cut_rad = sm_outer_rad + wmb_gap;
 178 wmb_x_screw = -sm_outer_rad + wmb_screw_around_x + wmb_screw_dia/2;
 179 function wmb_screw_thing_y_min(dia) = sqrt(
 180                        pow(wmb_mount_cut_rad, 2) -
 181                        pow(wmb_x_screw + dia/2, 2)
 182                        );
 183 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
 184 wmb_y_nut_min = wmb_screw_thing_y_min(wmb_nut_across);
 185 wmb_z_screw = 10; // XXX
 186
 187 smc_pos = [ 0, sm_inner_rad, 0 ];
 188
 189 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 190 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 191
 192 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 193 smc_max_y = smc_bolt_y + sm_bolt_y_over
 194   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 195 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 196   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 197
 198 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 199 catch_strap_thick = sm_main_thick;
 200
 201 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 202
 203 $fs= coarse ? 2.5 : 0.5;
 204 $fa= coarse ? 5 : 1;
 205
 206 include <poster-tube-lid-parametric.scad>
 207
 208 // bayonet definition
 209
 210 bayo_a = [ bayo_entry_x, 0 ];
 211 bayo_p = [ 0, bayo_entry_z ];
 212 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 213 bayo_m = [ bayo_inramp_x, bayo_behind ];
 214 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 215 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 216 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 217 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 218 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 219 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 220
 221 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 222 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 223 bayo_c = bayo_d + [0,-5];
 224 bayo_b = bayo_a + [0,-5];
 225
 226 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 227
 228 bayo_polygon = [ bayo_a,
 229                  bayo_b,
 230                  bayo_c,
 231                  bayo_d,
 232                  bayo_e,
 233                  bayo_f,
 234                  bayo_g,
 235                  bayo_h,
 236                  bayo_i,
 237                  bayo_j,
 238                  bayo_k,
 239                  bayo_l,
 240                  bayo_m,
 241                  bayo_n,
 242                  bayo_p ];
 243
 244 echo(bayo_polygon);
 245
 246 // CATCH
 247
 248 cppxC = 0.41 * sm_inner_rad * TAU;
 249
 250 // catch pin
 251
 252 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 253 // radius scaling due to nom and actual radius difference in
 254 // bayo entry construction
 255
 256 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 257 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 258 cppd = [ bayo_n[0]
 259          - catch_pin_slop - catch_pin_slop_x_extra,
 260          -catch_stalk_above_gap ];
 261 cppi = [ cppa[0], cppd[1] ];
 262 cppc = [ cppd[0], cppb[1] ];
 263 cpph = cppd + [0,-1] * catch_stalk_h;
 264 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 265 cppf = [ cppa[0], cppe[1] ];
 266 cppg = [ cppa[0], cpph[1] ];
 267 cppB = 0.5 * (cppf + cppe);
 268
 269 echo("RR", sm_inner_rad / bayo_nom_rad);
 270
 271 // catch assembly depression below pin
 272
 273 cppy6 = cppB[1] - (catch_knob_dia/2
 274                    + (cppc[1] - cppd[1])
 275                    + catch_stalk_below_gap);
 276 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 277 cpp11 = cpp7 + [1,0] * catch_cr;
 278 cppy9 = cppy6 + catch_strap_width * 1/3;
 279 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 280 cpp8 = cpp9 + [0,-1] * catch_cr;
 281 cpp10 = cpp8 + [-1,0] * catch_cr;
 282 cppC = [ cppxC, cpp9[1] ];
 283 cppD = cppC + [0,-1] * catch_strap_width;
 284
 285 // catch assembly stalk and so on
 286
 287 catch_cr3 = catch_cr + catch_stalk_h;
 288
 289 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 290 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 291 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 292 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 293 cpp2r = cpp2 + [1,0] * catch_cr;
 294 cpp2d = cpp2 + [0,-1] * catch_cr;
 295 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 296 cppA = [ -cppxC, cpp9[1] ];
 297 cppE = [ cppA[0], cppD[1] ];
 298
 299 catch_assembly_dy = -cppy9 + catch_strap_width;
 300
 301
 302 module MainProfile(){
 303   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 304   difference(){
 305     union(){
 306       translate(main_cnr_pos){
 307         intersection(){
 308           difference(){
 309             circle(r = main_cnr);
 310             circle(r = main_cnr * 0.5);
 311           }
 312           square([10,10]);
 313         }
 314       }
 315       polygon([[ -top_middle_dr,        middle_bot_z      ],
 316                [ -top_middle_dr,        top_z             ],
 317                [ main_cnr_pos[0],       top_z             ],
 318                [ side_thick,            main_cnr_pos[1]   ],
 319                [ side_thick,            -side_height      ],
 320                [ side_taper,            -side_height      ],
 321                [ 0,                     -rivet_posn       ],
 322                [ 0,                     by_oring_z        ],
 323                [ -oring_x_rad,          by_oring_z        ],
 324                ],
 325               convexity=10);
 326     }
 327     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 328       hull(){
 329       translate([ 0, oring_y_rad ])
 330         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 331         circle(oring_thick/2);
 332       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 333         circle(oring_thick/2);
 334     }
 335   }
 336 }
 337
 338 module StrapLoopProfile(){
 339   circle(r = strap_loop_thick/2);
 340 }
 341
 342 module StrapLoop(){ ////toplevel
 343   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 344   extralen = strap_loop_thick * 5;
 345
 346   intersection(){
 347     rotate([strap_loop_elevation, 0,0]){
 348       for (x= [ -1, +1 ] * bigrad) {
 349         translate([x, -extralen, 0])
 350           rotate([-90,0,0])
 351           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 352                          convexity=10)
 353           StrapLoopProfile();
 354       }
 355       translate([0, strap_loop_strlen, 0]){
 356         intersection(){
 357           rotate_extrude(convexity=10)
 358             translate([bigrad, 0,0])
 359             StrapLoopProfile();
 360           translate([0,50,0])
 361             cube([100,100,100], center=true);
 362         }
 363       }
 364     }
 365     translate([0, 50, 0])
 366       cube(100, center=true);
 367   }
 368 }
 369
 370 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 371   // nom_rad > real_rad
 372   rotate([0,0, atan2(offset, nom_rad) ]){
 373     intersection(){
 374       translate([-offset, -10, 0])
 375         rotate([90,0,0])
 376         linear_extrude(height= nom_rad*2, convexity=50)
 377         children(0);
 378       translate([0,0, -25])
 379         cylinder(h=50, r= real_rad);
 380       translate([0,0, -25])
 381         linear_extrude(height= 50, convexity=50)
 382         polygon([ [ 0,0 ],
 383                   [ -slice_size, -real_rad*2 ],
 384                   [ +slice_size, -real_rad*2 ] ]);
 385     }
 386   }
 387 }
 388
 389 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 390   offs = [ for (i=[ x_min :
 391                     slice_size :
 392                     x_max + slice_size ]) i ];
 393   echo (offs);
 394   for (off=offs)
 395     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 396     children(0);
 397 }
 398
 399 module BayonetCutout(){
 400   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 401                 bayo_nom_rad,
 402                 bayo_real_rad)
 403     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 404     polygon(bayo_polygon, convexity=10);
 405 }
 406
 407 module ProfilesDemo(){ ////toplevel
 408   translate([-10,0]) MainProfile();
 409   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 410 }
 411
 412 module LimitForHandling(){ ////toplevel
 413   hull() for (r=[0,180])
 414     rotate([0,0,r]) {
 415       for (rs=[-1,+1]) {
 416         for (xd=[0,1]) {
 417           rotate([0,0, rs * handling_angle/2]) {
 418             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 419                        main_dia/2 + side_thick - main_cnr,
 420                        top_z - main_cnr]) {
 421               mirror([0,0,1])
 422                 cylinder(r= main_cnr, h=50);
 423               sphere(main_cnr);
 424             }
 425           }
 426         }
 427       }
 428     }
 429   hull() rotate_extrude(convexity=10){
 430     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 431       circle(r = main_cnr);
 432       mirror([0,1]) square([ main_cnr, 50 ]);
 433     }
 434   }
 435   //cylinder(r= handling_dia/2, h=20);
 436 }
 437
 438 module Cover(){ ////toplevel
 439   render() difference(){
 440     intersection(){
 441       union(){
 442         rotate_extrude(convexity=10)
 443           translate([main_dia/2, 0])
 444           MainProfile();
 445         translate([0,0, middle_bot_z])
 446           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 447       }
 448       LimitForHandling();
 449     }
 450     for (r=[0,180]){
 451       rotate([0,0, r])
 452         translate([0,0, -side_height])
 453         BayonetCutout();
 454       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 455         translate([0,
 456                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 457                    oring_y_rad * 1.5])
 458         rotate([-oring_rm_angle, 0, 0])
 459         mirror([0,0,1])
 460         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 461     }
 462     for (r=[0 : 60 : 179]) {
 463       rotate([0,0, r]) {
 464         height = top_thick_middle - brace_above_below*2;
 465         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 466         cube(center=true, [ oring_bore - brace_end_shorter,
 467                             brace_hole_width, height ]);
 468       }
 469     }
 470   }
 471   if (enable_head_cups)
 472     for (r=[0,180])
 473       rotate([0,0,r])
 474         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 475                    -implheadcup_large_dia * .0,
 476                    middle_bot_z + 0.1])
 477         ImplHeadCup();
 478
 479 //  translate(strap_loop_thick * [-0.5, 0, +1])
 480 //    translate([handling_dia/2, 0, -side_height])
 481 //    rotate([0,180,0]) rotate([0,0,90])
 482 //    StrapLoop();
 483 }
 484
 485 module SavingHole(){
 486   translate([0,0, -10])
 487     cylinder(r= main_dia/2 - jig_rim, h=20);
 488 }
 489
 490 module Jig(){ ////toplevel
 491   difference(){
 492     union(){
 493       translate([0,0, -side_height]){
 494         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 495       }
 496       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 497         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 498     }
 499     translate([0,0, -side_height-1])
 500       cylinder(r= main_dia/2, h= side_height + 1);
 501     SavingHole();
 502     translate([0,0, -rivet_posn])
 503       rotate([90, 0,0])
 504       translate([0,0, -100])
 505       cylinder(r= jig_hole_dia/2, h = 200);
 506   }
 507 }
 508
 509 module CoverPrint(){ ////toplevel
 510   rotate([0,180,0]) Cover();
 511 }
 512
 513 module CoverTest2(){ ////toplevel
 514   difference(){
 515     Cover();
 516     SavingHole();
 517   }
 518 }
 519
 520 module CoverTest1(){ ////toplevel
 521   difference(){
 522     CoverTest2();
 523     difference(){
 524       for (r= [ 40, 147 ]){
 525         rotate([0,0, r]){
 526           translate([0,0, -10]) {
 527             cube([ main_dia*3, main_dia * .53, 18], center=true);
 528           }
 529         }
 530       }
 531 //      translate([ 50, 0, 0 ])
 532 //      cube([ 100,
 533 //             strap_loop_inside + strap_loop_thick*2 + 1,
 534 //             100 ],
 535 //           center=true);
 536     }
 537   }
 538 }
 539
 540 module ImplHeadCupTest(){ ////toplevel
 541   for (r=[0,180])
 542     rotate([0,0,r])
 543       translate([-17,0,0])
 544       ImplHeadCup();
 545 }
 546
 547 module SomeStrap(width, cut_width=0){
 548   // children(0) is to add, (1) subtract
 549   difference(){
 550     union(){
 551       cylinder(r=sm_outer_rad, h=width);
 552       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 553                            smc_max_y,
 554                            sm_closure_cnr,
 555                            width);
 556       children(0);
 557     }
 558     translate([0,0,-1])
 559       cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
 560     translate(smc_pos)
 561       StrapMountBolt(10, width);
 562     translate(smc_pos)
 563       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 564     children(1);
 565   }
 566 }
 567
 568 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 569   // positioned relative to smc_pos
 570   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 571              smc_bolt_y,
 572              strap_width/2]){
 573     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 574       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 575     }
 576     translate([ -sm_bolt_shaft/2, 0,0 ])
 577       rotate([0,-90,0])
 578       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 579                h=smc_bolt_nut_eff_thick + l_delta);
 580     translate([ sm_bolt_shaft/2, 0,0 ])
 581       rotate([0,90,0])
 582       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 583   }
 584 }
 585
 586 module StrapMountProtrusion(half_x, max_y, cnr, width){
 587   translate(smc_pos){
 588     linear_extrude(height=width, convexity=10){
 589       hull(){
 590         for (m = [0,1]) mirror([m,0,0]) {
 591           translate([-(half_x - cnr), max_y - cnr])
 592             circle(r=cnr);
 593           translate([-half_x, -sm_inner_rad])
 594             square([1,1]);
 595         }
 596       }
 597     }
 598   }
 599 }
 600
 601 module StrapMount(){ ////toplevel
 602   SomeStrap(sm_main_width){
 603     rotate([0,0,180]){
 604       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 605                            strap_loop_thick,
 606                            sm_closure_cnr,
 607                            sm_main_width);
 608       translate(smc_pos +
 609                 [0,0, sm_main_width] +
 610                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 611         StrapLoop();
 612     }
 613     union(){ };
 614   }
 615 }
 616
 617 module WallScrewHoleSlot(){ ////toplevel
 618   ds = [-1,+1] * wm_screw_slot/2;
 619   linextr_x_yz(-(wm_thick + 1), 1) {
 620     hull(){
 621       for (d = ds)
 622         translate([d, 0])
 623           circle(r = wm_screw_dia/2);
 624     }
 625   }
 626   hull(){
 627     for (d = ds){
 628       translate([0, d, 0]){
 629         linextr_x_yz(0, 1)
 630           circle(r = wm_screw_head/2);
 631         linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
 632           circle(r = wm_screw_dia/2);
 633       }
 634     }
 635   }
 636 }
 637
 638 module WallMountMounts(){
 639   linextr(0, wm_z_max){
 640     translate([ -sm_outer_rad, 0 ])
 641       rectfromto([ 0, -wm_y_max ],
 642                  [ wm_thick, wm_y_slot1_max ]);
 643   }
 644 }
 645 module WallMountScrewHoles(){
 646   translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
 647     translate([ 0, wm_y_slotc_screw, 0 ])
 648       WallScrewHoleSlot();
 649     translate([ 0, -wm_y_slotc_screw, 0 ])
 650       rotate([90,0,0])
 651       WallScrewHoleSlot();
 652   }
 653 }
 654
 655 module WallMount(){ ////toplevel
 656   SomeStrap(sm_main_width, wm_z_max + 2){
 657     WallMountMounts();
 658     WallMountScrewHoles();
 659   }
 660 }
 661
 662 module WallMountBaseMounts(){
 663 }
 664
 665 // screws, nuts, slots for nuts to go down into
 666 module WallMountBaseScrewsEtc(){
 667   for (my=[0,1]) {
 668     mirror([0, my, 0]) {
 669       translate([wmb_x_screw, 0, wmb_z_screw])
 670         linextr_y_xz(wmb_y_screw_end,
 671                      wmb_y_screw_end + wmb_screw_depth)
 672         circle(r = wmb_screw_dia/2);
 673 //      translate([
 674     }
 675   }
 676 }
 677 /*
 678
 679
 680       linextr(wmb_y_screw_end
 681       linextr(0, 20) {
 682         difference(){
 683           translate([ wmb_x_screw, wmb_y_screw_end ])
 684             rectfromto([ -wmb_screw_dia/2, 0 ],
 685                        [ +wmb_screw_dia/2, wmb_screw_depth ]);
 686         }
 687       }
 688     }
 689   }
 690 }*/
 691 //        circle(r = wmb_mount_cut_rad);
 692
 693 module WallMountForBase(){ ////toplevel
 694   SomeStrap(sm_main_width, wm_z_max + 2){
 695     union(){
 696       WallMountMounts();
 697     }
 698     union(){
 699       WallMountScrewHoles();
 700       %WallMountBaseScrewsEtc();
 701     }
 702   }
 703 }
 704
 705 module CatchAssemblyCoreProfile(){
 706   difference(){
 707     union(){
 708       hull(){
 709         translate(cpp3) circle(r= catch_cr3);
 710         polygon([ cpp3,
 711                   cpp2r,
 712                   cpp5,
 713                   cpph,
 714                   cppd
 715                   ]);
 716       }
 717       polygon([cppD,
 718                cppC,
 719                cpp9,
 720                cpp10,
 721                cpp11,
 722                cpp4,
 723                cpp2r,
 724                cpp2d,
 725                cppA,
 726                cppE
 727                ]);
 728       translate(cpp8) circle(r= catch_cr);
 729     }
 730     hull(){
 731       translate(cpp4) circle(r= catch_cr);
 732       translate(cpp5) circle(r= catch_cr);
 733       translate(cpp7) circle(r= catch_cr);
 734       polygon([cpp4,
 735                cppg,
 736                cpph,
 737                cpp10,
 738                cpp11,
 739                ]);
 740     }
 741     translate(cpp2) circle(r= catch_cr);
 742   }
 743   // if cpp11 is above cpp10, the subtracted hull above
 744   // can go down too far.  Ensure we do not cut off below cppy6.
 745   polygon([ cppE,
 746             cppD,
 747             cpp9,
 748             [ cpp9[0],            cppy6 ],
 749             [ cpp7[0] - catch_cr, cppy6 ],
 750             cpp2d
 751             ]);
 752 }
 753
 754 module CatchTipProfile(dy){
 755   ddy = [0,dy];
 756   intersection(){
 757     translate(cppF){
 758       difference(){
 759 //      circle(r = dist2d(cppF, cppd));
 760         //circle(r = dist2d(cppF, cppa));
 761       }
 762     }
 763     polygon([ cppa,
 764               cppi + ddy,
 765               cppd + ddy,
 766               cppc,
 767               cppb ]);
 768   }
 769 }
 770
 771 module CatchHeadProfile(){
 772   polygon([ cppd,
 773             cppd,
 774             cppi,
 775             cppf,
 776             cppe,
 777             cpph ]);
 778 }
 779
 780
 781 module CatchCore(){ /////toplevel
 782   linear_extrude(height=catch_strap_thick, convexity=10)
 783     CatchAssemblyCoreProfile();
 784
 785   hull(){
 786     linear_extrude(height=catch_head_th, convexity=10)
 787       CatchTipProfile(0);
 788     linear_extrude(height=catch_tip_th, convexity=10)
 789       CatchTipProfile(catch_tip_th - catch_head_th);
 790   }
 791
 792   linear_extrude(height=catch_head_th, convexity=10)
 793     CatchHeadProfile();
 794
 795   translate(concat(cppB,[0])) hull(){
 796     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 797       sphere(r = catch_knob_dia/2);
 798     cylinder(r = catch_knob_dia/2, h = 0.1);
 799   }
 800 }
 801
 802 module CatchPreDistort(){ /////toplevel
 803   scale(100 / sm_inner_rad)
 804     rotate([90,0,0])
 805     CatchCore();
 806 }
 807
 808 module CatchAssembly(){ /////toplevel
 809   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 810     translate([0,0, catch_assembly_dy])
 811     scale(sm_inner_rad / 100)
 812     import(str("poster-tube-lid,CatchPostDistort-fa",
 813                (coarse ? 20 : 3),
 814                ".stl"),
 815            convexity=20);
 816
 817   SomeStrap(catch_strap_width){
 818     union(){ }
 819     union(){
 820       translate([-200, -200, -200])
 821         cube([400, 200, 400]);
 822     }
 823   }
 824 }
 825
 826 module CatchDemo(){ /////toplevel
 827   color("blue") translate([0,0,
 828                            -catch_assembly_dy
 829              ])
 830     CatchAssembly();
 831   translate([0,0,+side_height
 832              ])
 833     Cover();
 834 }
 835
 836 module CatchDemoS(){ /////toplevel
 837   color("blue") translate([0,0,
 838              -catch_assembly_dy
 839              ])
 840     CatchAssembly();
 841   intersection(){
 842     translate([0,0,+side_height
 843                ])
 844       Cover();
 845     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 846   }
 847   color("black")
 848     translate([0,-33,0])
 849     cube([6.15, 2,2], center=true);
 850 }
 851
 852 module CatchPinProfileDemo(){ /////toplevel
 853   translate([0, 0 * -bayo_behind,0]) {
 854     echo("G ",
 855          bayo_n[0] - bayo_e[0]);
 856     color("blue") translate([0,0,
 857                              +1,
 858                ]) {
 859       CatchAssemblyCoreProfile();
 860       CatchHeadProfile();
 861     }
 862     translate([0,0,10])
 863       color("red")
 864       CatchTipProfile(0);
 865
 866     polygon(bayo_polygon, convexity=10);
 867
 868     // adhoc show a position
 869     color("purple")
 870     translate(concat(
 871                      cppa,
 872                      10
 873                      )) difference(){ circle(2.5); circle(2.0); }
 874
 875  }
 876 }
 877
 878 //ProfilesDemo();
 879 //BayonetCutout();
 880 //MainProfile();
 881 //Cover();
 882 //Jig();
 883 //CoverTest();