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_z = 6; // XXX
  99 wmb_screw_depth_min = 10;
 100 wmb_nut_across = 8; // XXX
 101 wmb_nut_around_min = 2; // XXX
 102 wmb_nut_behind_min = 3; // XXX
 103 wmb_nut_th = 4; // XXX
 104 wmb_ring_gap = 1.0;
 105
 106 catch_stalk_h = 4.5;
 107 catch_stalk_len = 50;
 108 catch_tip_th = 4;
 109 catch_head_th = 3;
 110
 111 catch_pin_slop = 0.25; // each side, and above
 112 catch_pin_slop_x_extra = 0.0; // only on one side
 113 catch_stalk_above_gap = 1.5;
 114 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 115
 116 catch_strap_width = 12;
 117 catch_stalk_base_width = 15;
 118
 119 catch_knob_dia = 6;
 120 catch_knob_above_gap = 5;
 121 catch_knob_height = 3.0;
 122
 123 catch_stalk_below_gap = 1.0;
 124 catch_stalk_beside_gap = 2.0;
 125
 126 // calculated
 127
 128 TAU = PI*2;
 129
 130 bayo_entry_x = bayo_entry;
 131 bayo_entry_z = bayo_entry;
 132 bayo_inramp_x = bayo_inramp;
 133 bayo_inramp_z = bayo_inramp;
 134
 135 oring_mid_dia = oring_bore + oring_thick;
 136 oring_outer_dia = oring_mid_dia + oring_thick;
 137
 138 oring_oblate = (1 - oring_compress);
 139
 140 oring_y_rad = oring_thick/2 * oring_oblate;
 141 oring_x_rad = oring_thick/2 / oring_oblate;
 142
 143 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 144
 145 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 146 side_thick = rivet_tall + over_rivet_wall;
 147
 148 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 149
 150 middle_bot_z = top_z - top_thick_middle;
 151
 152 bayo_top_z = bayo_behind + bayo_gap;
 153
 154 bayo_nom_rad = main_dia/2 + side_thick;
 155 bayo_real_rad = main_dia/2 + rivet_tall;
 156
 157 rivet_entry_width = rivet_width + side_rivet_gap;
 158
 159 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 160
 161 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 162 handling_angle = 45;
 163
 164 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 165 sm_outer_rad = sm_inner_rad + sm_main_thick;
 166
 167 wm_main_width = sm_main_width;
 168 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 169                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 170 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 171 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 172 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
 173 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 174 wm_y_slot1_max = wm_y_max + wm_screw_slot;
 175 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 176 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 177 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
 178 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 179
 180 wmb_mount_cut_rad = sm_outer_rad + wmb_ring_gap;
 181 wmb_nut_rad = wmb_nut_across / cos(30) * 0.5;
 182 wmb_x_screw = -sm_outer_rad + max(
 183                                   wmb_screw_around_x + wmb_screw_dia/2,
 184                                   wmb_nut_around_min + wmb_nut_across/2
 185                                   );
 186 function wmb_screw_thing_y_min(dia) = sqrt(
 187                        pow(wmb_mount_cut_rad, 2) -
 188                        pow(wmb_x_screw + dia/2, 2)
 189                        );
 190 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
 191 wmb_y_nut_min = wmb_screw_thing_y_min(wmb_nut_across + wmb_nut_around_min*2);
 192 wmb_y_mount_max = max(
 193                       wmb_y_nut_min + wmb_nut_th + wmb_nut_behind_min,
 194                       wmb_y_screw_end + wmb_screw_depth_min
 195                       );
 196 wmb_z_screw = max(
 197                   wmb_screw_around_z + wmb_screw_dia/2,
 198                   wmb_nut_around_min + wmb_nut_rad
 199                   );
 200 wmb_z_max = wmb_z_screw * 2;
 201
 202 smc_pos = [ 0, sm_inner_rad, 0 ];
 203
 204 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 205 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 206
 207 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 208 smc_max_y = smc_bolt_y + sm_bolt_y_over
 209   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 210 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 211   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 212
 213 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 214 catch_strap_thick = sm_main_thick;
 215
 216 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 217
 218 $fs= coarse ? 2.5 : 0.5;
 219 $fa= coarse ? 5 : 1;
 220
 221 include <poster-tube-lid-parametric.scad>
 222
 223 // bayonet definition
 224
 225 bayo_a = [ bayo_entry_x, 0 ];
 226 bayo_p = [ 0, bayo_entry_z ];
 227 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 228 bayo_m = [ bayo_inramp_x, bayo_behind ];
 229 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 230 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 231 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 232 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 233 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 234 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 235
 236 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 237 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 238 bayo_c = bayo_d + [0,-5];
 239 bayo_b = bayo_a + [0,-5];
 240
 241 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 242
 243 bayo_polygon = [ bayo_a,
 244                  bayo_b,
 245                  bayo_c,
 246                  bayo_d,
 247                  bayo_e,
 248                  bayo_f,
 249                  bayo_g,
 250                  bayo_h,
 251                  bayo_i,
 252                  bayo_j,
 253                  bayo_k,
 254                  bayo_l,
 255                  bayo_m,
 256                  bayo_n,
 257                  bayo_p ];
 258
 259 echo(bayo_polygon);
 260
 261 // CATCH
 262
 263 cppxC = 0.41 * sm_inner_rad * TAU;
 264
 265 // catch pin
 266
 267 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 268 // radius scaling due to nom and actual radius difference in
 269 // bayo entry construction
 270
 271 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 272 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 273 cppd = [ bayo_n[0]
 274          - catch_pin_slop - catch_pin_slop_x_extra,
 275          -catch_stalk_above_gap ];
 276 cppi = [ cppa[0], cppd[1] ];
 277 cppc = [ cppd[0], cppb[1] ];
 278 cpph = cppd + [0,-1] * catch_stalk_h;
 279 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 280 cppf = [ cppa[0], cppe[1] ];
 281 cppg = [ cppa[0], cpph[1] ];
 282 cppB = 0.5 * (cppf + cppe);
 283
 284 echo("RR", sm_inner_rad / bayo_nom_rad);
 285
 286 // catch assembly depression below pin
 287
 288 cppy6 = cppB[1] - (catch_knob_dia/2
 289                    + (cppc[1] - cppd[1])
 290                    + catch_stalk_below_gap);
 291 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 292 cpp11 = cpp7 + [1,0] * catch_cr;
 293 cppy9 = cppy6 + catch_strap_width * 1/3;
 294 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 295 cpp8 = cpp9 + [0,-1] * catch_cr;
 296 cpp10 = cpp8 + [-1,0] * catch_cr;
 297 cppC = [ cppxC, cpp9[1] ];
 298 cppD = cppC + [0,-1] * catch_strap_width;
 299
 300 // catch assembly stalk and so on
 301
 302 catch_cr3 = catch_cr + catch_stalk_h;
 303
 304 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 305 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 306 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 307 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 308 cpp2r = cpp2 + [1,0] * catch_cr;
 309 cpp2d = cpp2 + [0,-1] * catch_cr;
 310 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 311 cppA = [ -cppxC, cpp9[1] ];
 312 cppE = [ cppA[0], cppD[1] ];
 313
 314 catch_assembly_dy = -cppy9 + catch_strap_width;
 315
 316
 317 module MainProfile(){
 318   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 319   difference(){
 320     union(){
 321       translate(main_cnr_pos){
 322         intersection(){
 323           difference(){
 324             circle(r = main_cnr);
 325             circle(r = main_cnr * 0.5);
 326           }
 327           square([10,10]);
 328         }
 329       }
 330       polygon([[ -top_middle_dr,        middle_bot_z      ],
 331                [ -top_middle_dr,        top_z             ],
 332                [ main_cnr_pos[0],       top_z             ],
 333                [ side_thick,            main_cnr_pos[1]   ],
 334                [ side_thick,            -side_height      ],
 335                [ side_taper,            -side_height      ],
 336                [ 0,                     -rivet_posn       ],
 337                [ 0,                     by_oring_z        ],
 338                [ -oring_x_rad,          by_oring_z        ],
 339                ],
 340               convexity=10);
 341     }
 342     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 343       hull(){
 344       translate([ 0, oring_y_rad ])
 345         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 346         circle(oring_thick/2);
 347       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 348         circle(oring_thick/2);
 349     }
 350   }
 351 }
 352
 353 module StrapLoopProfile(){
 354   circle(r = strap_loop_thick/2);
 355 }
 356
 357 module StrapLoop(){ ////toplevel
 358   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 359   extralen = strap_loop_thick * 5;
 360
 361   intersection(){
 362     rotate([strap_loop_elevation, 0,0]){
 363       for (x= [ -1, +1 ] * bigrad) {
 364         translate([x, -extralen, 0])
 365           rotate([-90,0,0])
 366           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 367                          convexity=10)
 368           StrapLoopProfile();
 369       }
 370       translate([0, strap_loop_strlen, 0]){
 371         intersection(){
 372           rotate_extrude(convexity=10)
 373             translate([bigrad, 0,0])
 374             StrapLoopProfile();
 375           translate([0,50,0])
 376             cube([100,100,100], center=true);
 377         }
 378       }
 379     }
 380     translate([0, 50, 0])
 381       cube(100, center=true);
 382   }
 383 }
 384
 385 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 386   // nom_rad > real_rad
 387   rotate([0,0, atan2(offset, nom_rad) ]){
 388     intersection(){
 389       translate([-offset, -10, 0])
 390         rotate([90,0,0])
 391         linear_extrude(height= nom_rad*2, convexity=50)
 392         children(0);
 393       translate([0,0, -25])
 394         cylinder(h=50, r= real_rad);
 395       translate([0,0, -25])
 396         linear_extrude(height= 50, convexity=50)
 397         polygon([ [ 0,0 ],
 398                   [ -slice_size, -real_rad*2 ],
 399                   [ +slice_size, -real_rad*2 ] ]);
 400     }
 401   }
 402 }
 403
 404 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 405   offs = [ for (i=[ x_min :
 406                     slice_size :
 407                     x_max + slice_size ]) i ];
 408   echo (offs);
 409   for (off=offs)
 410     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 411     children(0);
 412 }
 413
 414 module BayonetCutout(){
 415   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 416                 bayo_nom_rad,
 417                 bayo_real_rad)
 418     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 419     polygon(bayo_polygon, convexity=10);
 420 }
 421
 422 module ProfilesDemo(){ ////toplevel
 423   translate([-10,0]) MainProfile();
 424   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 425 }
 426
 427 module LimitForHandling(){ ////toplevel
 428   hull() for (r=[0,180])
 429     rotate([0,0,r]) {
 430       for (rs=[-1,+1]) {
 431         for (xd=[0,1]) {
 432           rotate([0,0, rs * handling_angle/2]) {
 433             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 434                        main_dia/2 + side_thick - main_cnr,
 435                        top_z - main_cnr]) {
 436               mirror([0,0,1])
 437                 cylinder(r= main_cnr, h=50);
 438               sphere(main_cnr);
 439             }
 440           }
 441         }
 442       }
 443     }
 444   hull() rotate_extrude(convexity=10){
 445     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 446       circle(r = main_cnr);
 447       mirror([0,1]) square([ main_cnr, 50 ]);
 448     }
 449   }
 450   //cylinder(r= handling_dia/2, h=20);
 451 }
 452
 453 module Cover(){ ////toplevel
 454   render() difference(){
 455     intersection(){
 456       union(){
 457         rotate_extrude(convexity=10)
 458           translate([main_dia/2, 0])
 459           MainProfile();
 460         translate([0,0, middle_bot_z])
 461           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 462       }
 463       LimitForHandling();
 464     }
 465     for (r=[0,180]){
 466       rotate([0,0, r])
 467         translate([0,0, -side_height])
 468         BayonetCutout();
 469       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 470         translate([0,
 471                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 472                    oring_y_rad * 1.5])
 473         rotate([-oring_rm_angle, 0, 0])
 474         mirror([0,0,1])
 475         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 476     }
 477     for (r=[0 : 60 : 179]) {
 478       rotate([0,0, r]) {
 479         height = top_thick_middle - brace_above_below*2;
 480         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 481         cube(center=true, [ oring_bore - brace_end_shorter,
 482                             brace_hole_width, height ]);
 483       }
 484     }
 485   }
 486   if (enable_head_cups)
 487     for (r=[0,180])
 488       rotate([0,0,r])
 489         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 490                    -implheadcup_large_dia * .0,
 491                    middle_bot_z + 0.1])
 492         ImplHeadCup();
 493
 494 //  translate(strap_loop_thick * [-0.5, 0, +1])
 495 //    translate([handling_dia/2, 0, -side_height])
 496 //    rotate([0,180,0]) rotate([0,0,90])
 497 //    StrapLoop();
 498 }
 499
 500 module SavingHole(){
 501   translate([0,0, -10])
 502     cylinder(r= main_dia/2 - jig_rim, h=20);
 503 }
 504
 505 module Jig(){ ////toplevel
 506   difference(){
 507     union(){
 508       translate([0,0, -side_height]){
 509         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 510       }
 511       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 512         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 513     }
 514     translate([0,0, -side_height-1])
 515       cylinder(r= main_dia/2, h= side_height + 1);
 516     SavingHole();
 517     translate([0,0, -rivet_posn])
 518       rotate([90, 0,0])
 519       translate([0,0, -100])
 520       cylinder(r= jig_hole_dia/2, h = 200);
 521   }
 522 }
 523
 524 module CoverPrint(){ ////toplevel
 525   rotate([0,180,0]) Cover();
 526 }
 527
 528 module CoverTest2(){ ////toplevel
 529   difference(){
 530     Cover();
 531     SavingHole();
 532   }
 533 }
 534
 535 module CoverTest1(){ ////toplevel
 536   difference(){
 537     CoverTest2();
 538     difference(){
 539       for (r= [ 40, 147 ]){
 540         rotate([0,0, r]){
 541           translate([0,0, -10]) {
 542             cube([ main_dia*3, main_dia * .53, 18], center=true);
 543           }
 544         }
 545       }
 546 //      translate([ 50, 0, 0 ])
 547 //      cube([ 100,
 548 //             strap_loop_inside + strap_loop_thick*2 + 1,
 549 //             100 ],
 550 //           center=true);
 551     }
 552   }
 553 }
 554
 555 module ImplHeadCupTest(){ ////toplevel
 556   for (r=[0,180])
 557     rotate([0,0,r])
 558       translate([-17,0,0])
 559       ImplHeadCup();
 560 }
 561
 562 module SomeStrap(width, cut_width=0){
 563   // children(0) is to add, (1) subtract
 564   difference(){
 565     union(){
 566       cylinder(r=sm_outer_rad, h=width);
 567       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 568                            smc_max_y,
 569                            sm_closure_cnr,
 570                            width);
 571       children(0);
 572     }
 573     translate([0,0,-1])
 574       cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
 575     translate(smc_pos)
 576       StrapMountBolt(10, width);
 577     translate(smc_pos)
 578       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 579     children(1);
 580   }
 581 }
 582
 583 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 584   // positioned relative to smc_pos
 585   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 586              smc_bolt_y,
 587              strap_width/2]){
 588     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 589       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 590     }
 591     translate([ -sm_bolt_shaft/2, 0,0 ])
 592       rotate([0,-90,0])
 593       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 594                h=smc_bolt_nut_eff_thick + l_delta);
 595     translate([ sm_bolt_shaft/2, 0,0 ])
 596       rotate([0,90,0])
 597       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 598   }
 599 }
 600
 601 module StrapMountProtrusion(half_x, max_y, cnr, width){
 602   translate(smc_pos){
 603     linear_extrude(height=width, convexity=10){
 604       hull(){
 605         for (m = [0,1]) mirror([m,0,0]) {
 606           translate([-(half_x - cnr), max_y - cnr])
 607             circle(r=cnr);
 608           translate([-half_x, -sm_inner_rad])
 609             square([1,1]);
 610         }
 611       }
 612     }
 613   }
 614 }
 615
 616 module StrapMount(){ ////toplevel
 617   SomeStrap(sm_main_width){
 618     rotate([0,0,180]){
 619       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 620                            strap_loop_thick,
 621                            sm_closure_cnr,
 622                            sm_main_width);
 623       translate(smc_pos +
 624                 [0,0, sm_main_width] +
 625                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 626         StrapLoop();
 627     }
 628     union(){ };
 629   }
 630 }
 631
 632 module WallScrewHoleSlot(){ ////toplevel
 633   ds = [-1,+1] * wm_screw_slot/2;
 634   linextr_x_yz(-(wm_thick + 1), 1) {
 635     hull(){
 636       for (d = ds)
 637         translate([d, 0])
 638           circle(r = wm_screw_dia/2);
 639     }
 640   }
 641   hull(){
 642     for (d = ds){
 643       translate([0, d, 0]){
 644         linextr_x_yz(0, 1)
 645           circle(r = wm_screw_head/2);
 646         linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
 647           circle(r = wm_screw_dia/2);
 648       }
 649     }
 650   }
 651 }
 652
 653 module WallMountMounts(){
 654   linextr(0, wm_z_max){
 655     translate([ -sm_outer_rad, 0 ])
 656       rectfromto([ 0, -wm_y_max ],
 657                  [ wm_thick, wm_y_slot1_max ]);
 658   }
 659 }
 660 module WallMountScrewHoles(){
 661   translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
 662     translate([ 0, wm_y_slotc_screw, 0 ])
 663       WallScrewHoleSlot();
 664     translate([ 0, -wm_y_slotc_screw, 0 ])
 665       rotate([90,0,0])
 666       WallScrewHoleSlot();
 667   }
 668 }
 669
 670 module WallMount(){ ////toplevel
 671   SomeStrap(sm_main_width, wm_z_max + 2){
 672     WallMountMounts();
 673     WallMountScrewHoles();
 674   }
 675 }
 676
 677 module WallMountBaseMounts(){
 678   linextr(0, wmb_z_max) {
 679     difference(){
 680       rectfromto([ -sm_outer_rad,            -wmb_y_mount_max ],
 681                  [ -sm_outer_rad + wm_thick, +wmb_y_mount_max ]);
 682       circle(r = wmb_mount_cut_rad);
 683     }
 684   }
 685 }
 686
 687 // screws, nuts, slots for nuts to go down into
 688 module WallMountBaseScrewsEtc(){
 689   for (my=[0,1]) {
 690     mirror([0, my, 0]) {
 691       translate([wmb_x_screw, 0, wmb_z_screw]) {
 692         linextr_y_xz(wmb_y_screw_end,
 693                      wmb_y_screw_end + 100) // XXX change 100
 694           circle(r = wmb_screw_dia/2);
 695         linextr_y_xz(wmb_y_nut_min,
 696                      wmb_y_nut_min + wmb_nut_th){
 697           hull(){
 698             rotate(30)
 699               circle(r = wmb_nut_rad, $fn = 6);
 700             translate([0, 100]) // XXX change 100
 701               square(wmb_nut_across, center=true);
 702           }
 703         }
 704       }
 705     }
 706   }
 707 }
 708 /*
 709
 710
 711       linextr(wmb_y_screw_end
 712       linextr(0, 20) {
 713         difference(){
 714           translate([ wmb_x_screw, wmb_y_screw_end ])
 715             rectfromto([ -wmb_screw_dia/2, 0 ],
 716                        [ +wmb_screw_dia/2, wmb_screw_depth ]);
 717         }
 718       }
 719     }
 720   }
 721 }*/
 722
 723
 724 module WallMountForBase(){ ////toplevel
 725   SomeStrap(sm_main_width, wm_z_max + 2){
 726     union(){
 727       WallMountMounts();
 728       WallMountBaseMounts();
 729     }
 730     union(){
 731       WallMountScrewHoles();
 732       %WallMountBaseScrewsEtc();
 733     }
 734   }
 735 }
 736
 737 module CatchAssemblyCoreProfile(){
 738   difference(){
 739     union(){
 740       hull(){
 741         translate(cpp3) circle(r= catch_cr3);
 742         polygon([ cpp3,
 743                   cpp2r,
 744                   cpp5,
 745                   cpph,
 746                   cppd
 747                   ]);
 748       }
 749       polygon([cppD,
 750                cppC,
 751                cpp9,
 752                cpp10,
 753                cpp11,
 754                cpp4,
 755                cpp2r,
 756                cpp2d,
 757                cppA,
 758                cppE
 759                ]);
 760       translate(cpp8) circle(r= catch_cr);
 761     }
 762     hull(){
 763       translate(cpp4) circle(r= catch_cr);
 764       translate(cpp5) circle(r= catch_cr);
 765       translate(cpp7) circle(r= catch_cr);
 766       polygon([cpp4,
 767                cppg,
 768                cpph,
 769                cpp10,
 770                cpp11,
 771                ]);
 772     }
 773     translate(cpp2) circle(r= catch_cr);
 774   }
 775   // if cpp11 is above cpp10, the subtracted hull above
 776   // can go down too far.  Ensure we do not cut off below cppy6.
 777   polygon([ cppE,
 778             cppD,
 779             cpp9,
 780             [ cpp9[0],            cppy6 ],
 781             [ cpp7[0] - catch_cr, cppy6 ],
 782             cpp2d
 783             ]);
 784 }
 785
 786 module CatchTipProfile(dy){
 787   ddy = [0,dy];
 788   intersection(){
 789     translate(cppF){
 790       difference(){
 791 //      circle(r = dist2d(cppF, cppd));
 792         //circle(r = dist2d(cppF, cppa));
 793       }
 794     }
 795     polygon([ cppa,
 796               cppi + ddy,
 797               cppd + ddy,
 798               cppc,
 799               cppb ]);
 800   }
 801 }
 802
 803 module CatchHeadProfile(){
 804   polygon([ cppd,
 805             cppd,
 806             cppi,
 807             cppf,
 808             cppe,
 809             cpph ]);
 810 }
 811
 812
 813 module CatchCore(){ /////toplevel
 814   linear_extrude(height=catch_strap_thick, convexity=10)
 815     CatchAssemblyCoreProfile();
 816
 817   hull(){
 818     linear_extrude(height=catch_head_th, convexity=10)
 819       CatchTipProfile(0);
 820     linear_extrude(height=catch_tip_th, convexity=10)
 821       CatchTipProfile(catch_tip_th - catch_head_th);
 822   }
 823
 824   linear_extrude(height=catch_head_th, convexity=10)
 825     CatchHeadProfile();
 826
 827   translate(concat(cppB,[0])) hull(){
 828     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 829       sphere(r = catch_knob_dia/2);
 830     cylinder(r = catch_knob_dia/2, h = 0.1);
 831   }
 832 }
 833
 834 module CatchPreDistort(){ /////toplevel
 835   scale(100 / sm_inner_rad)
 836     rotate([90,0,0])
 837     CatchCore();
 838 }
 839
 840 module CatchAssembly(){ /////toplevel
 841   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 842     translate([0,0, catch_assembly_dy])
 843     scale(sm_inner_rad / 100)
 844     import(str("poster-tube-lid,CatchPostDistort-fa",
 845                (coarse ? 20 : 3),
 846                ".stl"),
 847            convexity=20);
 848
 849   SomeStrap(catch_strap_width){
 850     union(){ }
 851     union(){
 852       translate([-200, -200, -200])
 853         cube([400, 200, 400]);
 854     }
 855   }
 856 }
 857
 858 module CatchDemo(){ /////toplevel
 859   color("blue") translate([0,0,
 860                            -catch_assembly_dy
 861              ])
 862     CatchAssembly();
 863   translate([0,0,+side_height
 864              ])
 865     Cover();
 866 }
 867
 868 module CatchDemoS(){ /////toplevel
 869   color("blue") translate([0,0,
 870              -catch_assembly_dy
 871              ])
 872     CatchAssembly();
 873   intersection(){
 874     translate([0,0,+side_height
 875                ])
 876       Cover();
 877     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 878   }
 879   color("black")
 880     translate([0,-33,0])
 881     cube([6.15, 2,2], center=true);
 882 }
 883
 884 module CatchPinProfileDemo(){ /////toplevel
 885   translate([0, 0 * -bayo_behind,0]) {
 886     echo("G ",
 887          bayo_n[0] - bayo_e[0]);
 888     color("blue") translate([0,0,
 889                              +1,
 890                ]) {
 891       CatchAssemblyCoreProfile();
 892       CatchHeadProfile();
 893     }
 894     translate([0,0,10])
 895       color("red")
 896       CatchTipProfile(0);
 897
 898     polygon(bayo_polygon, convexity=10);
 899
 900     // adhoc show a position
 901     color("purple")
 902     translate(concat(
 903                      cppa,
 904                      10
 905                      )) difference(){ circle(2.5); circle(2.0); }
 906
 907  }
 908 }
 909
 910 //ProfilesDemo();
 911 //BayonetCutout();
 912 //MainProfile();
 913 //Cover();
 914 //Jig();
 915 //CoverTest();