tube-crossdrill-jig.scad

   1 // -*- C -*-
   2
   3 //$fs=0.1;
   4 //$fa=3;
   5 $fs=0.2;
   6 $fa=6;
   7
   8 rearwallthick = 3;
   9 basethick = 2;
  10 mainframeendthick = 2.5;
  11
  12 tubedia = 16 + 0.8;
  13 tubetubethick=2;
  14 tubetubetopslop=1;
  15
  16 boltholedia = 6.5 + 0.5;
  17 boltholeslotshorter = 6;
  18 mainframeholedia = 5 + 1.0;
  19
  20 // "slot" refers to the things in the base of the drill press stand
  21 backslotedgespace = 59;
  22 slotwidth = 11.5 - 0.5;
  23 backslotmid2screwhole = 17;
  24 slotplugheight = 5.5;
  25 slotplugshorterlen =10;
  26 slotpluglongerlen = 20;
  27
  28 slotslope = 11.0 / 18.5;
  29
  30 // "keepslot" refers to the screws in the wooden jig block
  31 keepslotstartz = 20;
  32 keepslotlen = 18;
  33 keepslotx = backslotedgespace / 2;
  34 keepslotwidth = 4;
  35
  36 mainframeextraside = 12;
  37 mainframeextrafront = 15;
  38
  39 rearwallstrengthwidth = 10;
  40 keepslotclear = 10;
  41
  42 // computed values
  43
  44 slotslopediag = sqrt(1 + slotslope*slotslope);
  45 slotwidthx = slotwidth * slotslopediag;
  46
  47 slotxperlen = slotslope / slotslopediag;
  48 slotyperlen =         1 / slotslopediag;
  49
  50 mainframeholex = backslotedgespace/2 + slotpluglongerlen * slotxperlen
  51   + 0.5 * slotwidth * slotyperlen;
  52
  53 mainframeholey = -slotpluglongerlen * slotyperlen
  54   + 0.5 * slotwidth * slotxperlen;
  55
  56 mainframemaxx = mainframeholex + mainframeextraside;
  57 mainframeminy = mainframeholey - mainframeextrafront;
  58 mainframemaxz = keepslotstartz + keepslotlen;
  59
  60 module MainFrame(){
  61   for (m=[0,1]) {
  62     mirror([m,0,0]) {
  63       translate([-1, mainframeminy, 0])
  64         cube([mainframemaxx+1, -mainframeminy, basethick]);
  65       translate([-1, -rearwallthick, 0])
  66         cube([mainframemaxx+1, rearwallthick, mainframemaxz]);
  67
  68       for (x=[keepslotx - keepslotclear, mainframemaxx - 0.5]) {
  69         translate([x,0,0])
  70           rotate([90,0,-90])
  71           linear_extrude(height=mainframeendthick)
  72           polygon([[-mainframeminy, 0],
  73                    [0, mainframemaxz],
  74                    [0, 0]]);
  75       }
  76
  77       translate([backslotedgespace/2, 0, 1])
  78         mirror([0,0,1])
  79         linear_extrude(height=slotplugheight+1)
  80         polygon([[0,0],
  81                  [slotwidthx, 0],
  82                  [slotwidthx + slotplugshorterlen * slotxperlen,
  83                   -slotplugshorterlen * slotyperlen],
  84                  [slotpluglongerlen * slotxperlen,
  85                   -slotpluglongerlen * slotyperlen]]);
  86       translate([-1,
  87                  -rearwallthick - boltholeslotshorter + 0.2,
  88                  tubedia + tubetubetopslop + tubetubethick + 4])
  89         cube([keepslotx - keepslotclear + 1,
  90               boltholeslotshorter + 0.5,
  91               rearwallstrengthwidth]);
  92     }
  93   }
  94 }
  95
  96 module TubeThing(extralen, dia, extraheight, underheight){
  97   effheight = tubetubetopslop + extraheight + underheight;
  98   len = -mainframeminy + extralen * 2;
  99   translate([0, mainframeminy - extralen, -underheight]) {
 100     translate([0,0, dia/2 + effheight])
 101       rotate([-90,0,0]) cylinder(h=len, r=dia/2);
 102     translate([-dia/2, 0, 0])
 103       cube([dia, len, effheight + dia/2]);
 104   }
 105 }
 106
 107 module Jig(){
 108   difference(){
 109     union(){
 110       MainFrame();
 111       TubeThing(0, tubedia+tubetubethick*2, -tubetubethick, 0);
 112     }
 113     union(){
 114       translate([0,0,-0.1])
 115         TubeThing(10, tubedia, 0, 5);
 116       translate([-boltholedia/2, mainframeminy - 1, -5])
 117         cube([boltholedia,
 118               -mainframeminy + 1 - rearwallthick - boltholeslotshorter,
 119               mainframemaxz + 10]);
 120       for (m=[0,1]) {
 121         mirror([m,0,0]) {
 122           translate([mainframeholex, mainframeholey, -30])
 123             cylinder(h=basethick+40, r=mainframeholedia/2);
 124           translate([keepslotx - keepslotwidth/2,
 125                      -10, keepslotstartz])
 126             cube([keepslotwidth, 20, keepslotlen + 10]);
 127         }
 128       }
 129     }
 130   }
 131 }
 132
 133 //MainFrame();
 134 //TubeThing(0, tubedia);
 135
 136 rotate([-90,0,0])
 137   Jig();