// -*- C -*-

patbox_side = 87;
patbox_centres = 60.3;

lid_thinboxbase_overlap = 5;
lid_fatbox_overlap = 12;

lid_thinbox_h = 9;
lid_fatbox_h = 24;
lid_fatbox_switches_h = 6+2;

lid_max_switches_w = 70;
lid_switches_y_slop = 3;

total_len = 260;
thinbox_len = 87;

lid_top_wall = 1.5;
lid_front_wall = 1.5;
lid_side_wall = 1.5;

peg_engage_depth = 1;
peg_engage_dia = 6.0;
peg_main_dia = 9;
peg_max_dia = 15;
peg_inner_dia = 3.5;
peg_top_thick = 1;
peg_straight_len = 3;

peg_inner_slop = 0.2;
peg_outer_slop = 0.1;

peg_slope = 1;

lid_side_slop = 0.5;

// computed

lid_inner_max_h =
  lid_thinboxbase_overlap + lid_fatbox_h + lid_fatbox_switches_h;
lid_inner_min_h = lid_fatbox_overlap + lid_fatbox_switches_h;

lid_inner_kink = [thinbox_len, thinbox_len*2];

lid_inner_w = patbox_side + lid_side_slop;

lid_rail_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop;

lid_rail_h = lid_fatbox_switches_h;

echo(lid_rail_w);

peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope;

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],
	   [total_len,         lid_inner_min_h],
	   [total_len,         -lid_front_wall],
	   [-lid_top_wall,     -lid_front_wall]]);
}

module LidSide(){
  overlap = [0.1, 0.1, 0.1];

  // main side profile
  rotate([90,0,0])
    linear_extrude(height= lid_side_wall)
    LidSideProfile();

  // rail
  translate(-overlap)
    cube(overlap + [total_len, lid_rail_w, lid_rail_h]);

  // lid front
  translate([-0.1, -0.1, -lid_front_wall])
    cube([total_len+0.1, lid_inner_w/2 + 0.2, lid_front_wall]);

  // 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]);
}

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]]);
}

//LidSide();
PegProfile();