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