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_head_dia = 10; // XXX
  98 wmb_screw_around_x = 4; // XXX
  99 wmb_screw_around_z = 6; // XXX
 100 wmb_screw_depth_min = 10;
 101 web_screw_len = 15 + 1; // XXX
 102 wmb_nut_across = 8; // XXX
 103 wmb_nut_around_min = 2; // XXX
 104 wmb_nut_behind_min = 5;
 105 wmb_nut_th = 4; // XXX
 106 wmb_mount_wall = 4.5;
 107 wmb_mount_gap_xy = 0.5;
 108 wmb_mount_y_width = 10;
 109 wmb_ring_gap = 1.0;
 110
 111 catch_stalk_h = 4.5;
 112 catch_stalk_len = 50;
 113 catch_tip_th = 4;
 114 catch_head_th = 3;
 115
 116 catch_pin_slop = 0.25; // each side, and above
 117 catch_pin_slop_x_extra = 0.0; // only on one side
 118 catch_stalk_above_gap = 1.5;
 119 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 120
 121 catch_strap_width = 12;
 122 catch_stalk_base_width = 15;
 123
 124 catch_knob_dia = 6;
 125 catch_knob_above_gap = 5;
 126 catch_knob_height = 3.0;
 127
 128 catch_stalk_below_gap = 1.0;
 129 catch_stalk_beside_gap = 2.0;
 130
 131 // calculated
 132
 133 TAU = PI*2;
 134
 135 bayo_entry_x = bayo_entry;
 136 bayo_entry_z = bayo_entry;
 137 bayo_inramp_x = bayo_inramp;
 138 bayo_inramp_z = bayo_inramp;
 139
 140 oring_mid_dia = oring_bore + oring_thick;
 141 oring_outer_dia = oring_mid_dia + oring_thick;
 142
 143 oring_oblate = (1 - oring_compress);
 144
 145 oring_y_rad = oring_thick/2 * oring_oblate;
 146 oring_x_rad = oring_thick/2 / oring_oblate;
 147
 148 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 149
 150 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 151 side_thick = rivet_tall + over_rivet_wall;
 152
 153 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 154
 155 middle_bot_z = top_z - top_thick_middle;
 156
 157 bayo_top_z = bayo_behind + bayo_gap;
 158
 159 bayo_nom_rad = main_dia/2 + side_thick;
 160 bayo_real_rad = main_dia/2 + rivet_tall;
 161
 162 rivet_entry_width = rivet_width + side_rivet_gap;
 163
 164 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 165
 166 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 167 handling_angle = 45;
 168
 169 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 170 sm_outer_rad = sm_inner_rad + sm_main_thick;
 171
 172 wm_main_width = sm_main_width;
 173 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 174                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 175 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 176 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 177 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
 178 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 179 wm_y_slot1_max = wm_y_max + wm_screw_slot;
 180 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 181 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 182 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
 183 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 184
 185 wmb_mount_cut_rad = sm_outer_rad + wmb_ring_gap;
 186 wmb_nut_rad = wmb_nut_across / cos(30) * 0.5;
 187 wmb_x_screw_plus_around_r = max(
 188                                 wmb_screw_around_x + wmb_screw_dia/2,
 189                                 wmb_nut_around_min + wmb_nut_across/2
 190                                 );
 191 wmb_x_screw = -sm_outer_rad + wmb_x_screw_plus_around_r;
 192 wmb_x_outer = -sm_outer_rad + wmb_x_screw_plus_around_r * 2;
 193 function wmb_screw_thing_y_min(dia) = sqrt(
 194                        pow(wmb_mount_cut_rad, 2) -
 195                        pow(wmb_x_screw + dia/2, 2)
 196                        );
 197 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
 198 wmb_y_nut_min = wmb_screw_thing_y_min(wmb_nut_across + wmb_nut_around_min*2);
 199 wmb_y_mount_max = max(
 200                       wmb_y_nut_min + wmb_nut_th + wmb_nut_behind_min,
 201                       wmb_y_screw_end + wmb_screw_depth_min
 202                       );
 203 wmb_z_screw = max(
 204                   wmb_screw_around_z + wmb_screw_dia/2,
 205                   wmb_nut_around_min + wmb_nut_rad
 206                   );
 207 wmb_z_max = wmb_z_screw * 2;
 208 wmbb_y_max = wmb_y_mount_max + wmb_mount_gap_xy + wmb_mount_wall;
 209 wmbb_x_outer = wmb_x_outer + (wmb_mount_gap_xy + wmb_mount_wall);
 210 wmbb_z_min = -20; // XXX
 211
 212 smc_pos = [ 0, sm_inner_rad, 0 ];
 213
 214 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 215 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 216
 217 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 218 smc_max_y = smc_bolt_y + sm_bolt_y_over
 219   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 220 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 221   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 222
 223 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 224 catch_strap_thick = sm_main_thick;
 225
 226 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 227
 228 $fs= coarse ? 2.5 : 0.5;
 229 $fa= coarse ? 5 : 1;
 230
 231 include <poster-tube-lid-parametric.scad>
 232
 233 // bayonet definition
 234
 235 bayo_a = [ bayo_entry_x, 0 ];
 236 bayo_p = [ 0, bayo_entry_z ];
 237 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 238 bayo_m = [ bayo_inramp_x, bayo_behind ];
 239 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 240 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 241 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 242 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 243 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 244 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 245
 246 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 247 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 248 bayo_c = bayo_d + [0,-5];
 249 bayo_b = bayo_a + [0,-5];
 250
 251 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 252
 253 bayo_polygon = [ bayo_a,
 254                  bayo_b,
 255                  bayo_c,
 256                  bayo_d,
 257                  bayo_e,
 258                  bayo_f,
 259                  bayo_g,
 260                  bayo_h,
 261                  bayo_i,
 262                  bayo_j,
 263                  bayo_k,
 264                  bayo_l,
 265                  bayo_m,
 266                  bayo_n,
 267                  bayo_p ];
 268
 269 echo(bayo_polygon);
 270
 271 // CATCH
 272
 273 cppxC = 0.41 * sm_inner_rad * TAU;
 274
 275 // catch pin
 276
 277 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 278 // radius scaling due to nom and actual radius difference in
 279 // bayo entry construction
 280
 281 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 282 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 283 cppd = [ bayo_n[0]
 284          - catch_pin_slop - catch_pin_slop_x_extra,
 285          -catch_stalk_above_gap ];
 286 cppi = [ cppa[0], cppd[1] ];
 287 cppc = [ cppd[0], cppb[1] ];
 288 cpph = cppd + [0,-1] * catch_stalk_h;
 289 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 290 cppf = [ cppa[0], cppe[1] ];
 291 cppg = [ cppa[0], cpph[1] ];
 292 cppB = 0.5 * (cppf + cppe);
 293
 294 echo("RR", sm_inner_rad / bayo_nom_rad);
 295
 296 // catch assembly depression below pin
 297
 298 cppy6 = cppB[1] - (catch_knob_dia/2
 299                    + (cppc[1] - cppd[1])
 300                    + catch_stalk_below_gap);
 301 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 302 cpp11 = cpp7 + [1,0] * catch_cr;
 303 cppy9 = cppy6 + catch_strap_width * 1/3;
 304 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 305 cpp8 = cpp9 + [0,-1] * catch_cr;
 306 cpp10 = cpp8 + [-1,0] * catch_cr;
 307 cppC = [ cppxC, cpp9[1] ];
 308 cppD = cppC + [0,-1] * catch_strap_width;
 309
 310 // catch assembly stalk and so on
 311
 312 catch_cr3 = catch_cr + catch_stalk_h;
 313
 314 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 315 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 316 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 317 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 318 cpp2r = cpp2 + [1,0] * catch_cr;
 319 cpp2d = cpp2 + [0,-1] * catch_cr;
 320 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 321 cppA = [ -cppxC, cpp9[1] ];
 322 cppE = [ cppA[0], cppD[1] ];
 323
 324 catch_assembly_dy = -cppy9 + catch_strap_width;
 325
 326
 327 module MainProfile(){
 328   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 329   difference(){
 330     union(){
 331       translate(main_cnr_pos){
 332         intersection(){
 333           difference(){
 334             circle(r = main_cnr);
 335             circle(r = main_cnr * 0.5);
 336           }
 337           square([10,10]);
 338         }
 339       }
 340       polygon([[ -top_middle_dr,        middle_bot_z      ],
 341                [ -top_middle_dr,        top_z             ],
 342                [ main_cnr_pos[0],       top_z             ],
 343                [ side_thick,            main_cnr_pos[1]   ],
 344                [ side_thick,            -side_height      ],
 345                [ side_taper,            -side_height      ],
 346                [ 0,                     -rivet_posn       ],
 347                [ 0,                     by_oring_z        ],
 348                [ -oring_x_rad,          by_oring_z        ],
 349                ],
 350               convexity=10);
 351     }
 352     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 353       hull(){
 354       translate([ 0, oring_y_rad ])
 355         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 356         circle(oring_thick/2);
 357       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 358         circle(oring_thick/2);
 359     }
 360   }
 361 }
 362
 363 module StrapLoopProfile(){
 364   circle(r = strap_loop_thick/2);
 365 }
 366
 367 module StrapLoop(){ ////toplevel
 368   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 369   extralen = strap_loop_thick * 5;
 370
 371   intersection(){
 372     rotate([strap_loop_elevation, 0,0]){
 373       for (x= [ -1, +1 ] * bigrad) {
 374         translate([x, -extralen, 0])
 375           rotate([-90,0,0])
 376           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 377                          convexity=10)
 378           StrapLoopProfile();
 379       }
 380       translate([0, strap_loop_strlen, 0]){
 381         intersection(){
 382           rotate_extrude(convexity=10)
 383             translate([bigrad, 0,0])
 384             StrapLoopProfile();
 385           translate([0,50,0])
 386             cube([100,100,100], center=true);
 387         }
 388       }
 389     }
 390     translate([0, 50, 0])
 391       cube(100, center=true);
 392   }
 393 }
 394
 395 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 396   // nom_rad > real_rad
 397   rotate([0,0, atan2(offset, nom_rad) ]){
 398     intersection(){
 399       translate([-offset, -10, 0])
 400         rotate([90,0,0])
 401         linear_extrude(height= nom_rad*2, convexity=50)
 402         children(0);
 403       translate([0,0, -25])
 404         cylinder(h=50, r= real_rad);
 405       translate([0,0, -25])
 406         linear_extrude(height= 50, convexity=50)
 407         polygon([ [ 0,0 ],
 408                   [ -slice_size, -real_rad*2 ],
 409                   [ +slice_size, -real_rad*2 ] ]);
 410     }
 411   }
 412 }
 413
 414 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 415   offs = [ for (i=[ x_min :
 416                     slice_size :
 417                     x_max + slice_size ]) i ];
 418   echo (offs);
 419   for (off=offs)
 420     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 421     children(0);
 422 }
 423
 424 module BayonetCutout(){
 425   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 426                 bayo_nom_rad,
 427                 bayo_real_rad)
 428     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 429     polygon(bayo_polygon, convexity=10);
 430 }
 431
 432 module ProfilesDemo(){ ////toplevel
 433   translate([-10,0]) MainProfile();
 434   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 435 }
 436
 437 module LimitForHandling(){ ////toplevel
 438   hull() for (r=[0,180])
 439     rotate([0,0,r]) {
 440       for (rs=[-1,+1]) {
 441         for (xd=[0,1]) {
 442           rotate([0,0, rs * handling_angle/2]) {
 443             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 444                        main_dia/2 + side_thick - main_cnr,
 445                        top_z - main_cnr]) {
 446               mirror([0,0,1])
 447                 cylinder(r= main_cnr, h=50);
 448               sphere(main_cnr);
 449             }
 450           }
 451         }
 452       }
 453     }
 454   hull() rotate_extrude(convexity=10){
 455     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 456       circle(r = main_cnr);
 457       mirror([0,1]) square([ main_cnr, 50 ]);
 458     }
 459   }
 460   //cylinder(r= handling_dia/2, h=20);
 461 }
 462
 463 module Cover(){ ////toplevel
 464   render() difference(){
 465     intersection(){
 466       union(){
 467         rotate_extrude(convexity=10)
 468           translate([main_dia/2, 0])
 469           MainProfile();
 470         translate([0,0, middle_bot_z])
 471           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 472       }
 473       LimitForHandling();
 474     }
 475     for (r=[0,180]){
 476       rotate([0,0, r])
 477         translate([0,0, -side_height])
 478         BayonetCutout();
 479       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 480         translate([0,
 481                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 482                    oring_y_rad * 1.5])
 483         rotate([-oring_rm_angle, 0, 0])
 484         mirror([0,0,1])
 485         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 486     }
 487     for (r=[0 : 60 : 179]) {
 488       rotate([0,0, r]) {
 489         height = top_thick_middle - brace_above_below*2;
 490         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 491         cube(center=true, [ oring_bore - brace_end_shorter,
 492                             brace_hole_width, height ]);
 493       }
 494     }
 495   }
 496   if (enable_head_cups)
 497     for (r=[0,180])
 498       rotate([0,0,r])
 499         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 500                    -implheadcup_large_dia * .0,
 501                    middle_bot_z + 0.1])
 502         ImplHeadCup();
 503
 504 //  translate(strap_loop_thick * [-0.5, 0, +1])
 505 //    translate([handling_dia/2, 0, -side_height])
 506 //    rotate([0,180,0]) rotate([0,0,90])
 507 //    StrapLoop();
 508 }
 509
 510 module SavingHole(){
 511   translate([0,0, -10])
 512     cylinder(r= main_dia/2 - jig_rim, h=20);
 513 }
 514
 515 module Jig(){ ////toplevel
 516   difference(){
 517     union(){
 518       translate([0,0, -side_height]){
 519         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 520       }
 521       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 522         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 523     }
 524     translate([0,0, -side_height-1])
 525       cylinder(r= main_dia/2, h= side_height + 1);
 526     SavingHole();
 527     translate([0,0, -rivet_posn])
 528       rotate([90, 0,0])
 529       translate([0,0, -100])
 530       cylinder(r= jig_hole_dia/2, h = 200);
 531   }
 532 }
 533
 534 module CoverPrint(){ ////toplevel
 535   rotate([0,180,0]) Cover();
 536 }
 537
 538 module CoverTest2(){ ////toplevel
 539   difference(){
 540     Cover();
 541     SavingHole();
 542   }
 543 }
 544
 545 module CoverTest1(){ ////toplevel
 546   difference(){
 547     CoverTest2();
 548     difference(){
 549       for (r= [ 40, 147 ]){
 550         rotate([0,0, r]){
 551           translate([0,0, -10]) {
 552             cube([ main_dia*3, main_dia * .53, 18], center=true);
 553           }
 554         }
 555       }
 556 //      translate([ 50, 0, 0 ])
 557 //      cube([ 100,
 558 //             strap_loop_inside + strap_loop_thick*2 + 1,
 559 //             100 ],
 560 //           center=true);
 561     }
 562   }
 563 }
 564
 565 module ImplHeadCupTest(){ ////toplevel
 566   for (r=[0,180])
 567     rotate([0,0,r])
 568       translate([-17,0,0])
 569       ImplHeadCup();
 570 }
 571
 572 module SomeStrap(width, cut_width=0){
 573   // children(0) is to add, (1) subtract
 574   difference(){
 575     union(){
 576       cylinder(r=sm_outer_rad, h=width);
 577       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 578                            smc_max_y,
 579                            sm_closure_cnr,
 580                            width);
 581       children(0);
 582     }
 583     translate([0,0,-1])
 584       cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
 585     translate(smc_pos)
 586       StrapMountBolt(10, width);
 587     translate(smc_pos)
 588       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 589     children(1);
 590   }
 591 }
 592
 593 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 594   // positioned relative to smc_pos
 595   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 596              smc_bolt_y,
 597              strap_width/2]){
 598     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 599       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 600     }
 601     translate([ -sm_bolt_shaft/2, 0,0 ])
 602       rotate([0,-90,0])
 603       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 604                h=smc_bolt_nut_eff_thick + l_delta);
 605     translate([ sm_bolt_shaft/2, 0,0 ])
 606       rotate([0,90,0])
 607       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 608   }
 609 }
 610
 611 module StrapMountProtrusion(half_x, max_y, cnr, width){
 612   translate(smc_pos){
 613     linear_extrude(height=width, convexity=10){
 614       hull(){
 615         for (m = [0,1]) mirror([m,0,0]) {
 616           translate([-(half_x - cnr), max_y - cnr])
 617             circle(r=cnr);
 618           translate([-half_x, -sm_inner_rad])
 619             square([1,1]);
 620         }
 621       }
 622     }
 623   }
 624 }
 625
 626 module StrapMount(){ ////toplevel
 627   SomeStrap(sm_main_width){
 628     rotate([0,0,180]){
 629       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 630                            strap_loop_thick,
 631                            sm_closure_cnr,
 632                            sm_main_width);
 633       translate(smc_pos +
 634                 [0,0, sm_main_width] +
 635                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 636         StrapLoop();
 637     }
 638     union(){ };
 639   }
 640 }
 641
 642 module WallScrewHoleSlot(){ ////toplevel
 643   ds = [-1,+1] * wm_screw_slot/2;
 644   linextr_x_yz(-(wm_thick + 1), 1) {
 645     hull(){
 646       for (d = ds)
 647         translate([d, 0])
 648           circle(r = wm_screw_dia/2);
 649     }
 650   }
 651   hull(){
 652     for (d = ds){
 653       translate([0, d, 0]){
 654         linextr_x_yz(0, 1)
 655           circle(r = wm_screw_head/2);
 656         linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
 657           circle(r = wm_screw_dia/2);
 658       }
 659     }
 660   }
 661 }
 662
 663 module WallMountMounts(){
 664   linextr(0, wm_z_max){
 665     translate([ -sm_outer_rad, 0 ])
 666       rectfromto([ 0, -wm_y_max ],
 667                  [ wm_thick, wm_y_slot1_max ]);
 668   }
 669 }
 670 module WallMountScrewHoles(){
 671   translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
 672     translate([ 0, wm_y_slotc_screw, 0 ])
 673       WallScrewHoleSlot();
 674     translate([ 0, -wm_y_slotc_screw, 0 ])
 675       rotate([90,0,0])
 676       WallScrewHoleSlot();
 677   }
 678 }
 679
 680 module WallMount(){ ////toplevel
 681   SomeStrap(sm_main_width, wm_z_max + 2){
 682     WallMountMounts();
 683     WallMountScrewHoles();
 684   }
 685 }
 686
 687 module WallMountBaseRingCut(){
 688   circle(r = wmb_mount_cut_rad);
 689 }
 690
 691 module WallMountBaseMounts(){
 692   linextr(0, wmb_z_max) {
 693     difference(){
 694       rectfromto([ -sm_outer_rad,            -wmb_y_mount_max ],
 695                  [ wmb_x_outer, +wmb_y_mount_max ]);
 696       WallMountBaseRingCut();
 697     }
 698   }
 699 }
 700
 701 // screws, nuts, slots for nuts to go down into
 702 module WallMountBaseScrewsEtc(){ ////toplevel
 703   for (my=[0,1]) {
 704     mirror([0, my, 0]) {
 705       translate([wmb_x_screw, 0, wmb_z_screw]) {
 706         linextr_y_xz(wmb_y_screw_end,
 707                      wmb_y_screw_end + 100) // XXX change 100
 708           circle(r = wmb_screw_dia/2);
 709         linextr_y_xz(wmb_y_screw_end + web_screw_len,
 710                      wmb_y_screw_end + 100) // XXX change 100
 711           circle(r = wmb_screw_head_dia/2);
 712         linextr_y_xz(wmb_y_nut_min,
 713                      wmb_y_nut_min + wmb_nut_th){
 714           hull(){
 715             rotate(30)
 716               circle(r = wmb_nut_rad, $fn = 6);
 717             translate([0, 100]) // XXX change 100
 718               square(wmb_nut_across, center=true);
 719           }
 720         }
 721       }
 722     }
 723   }
 724 }
 725
 726 module WallMountForBase(){ ////toplevel
 727   SomeStrap(sm_main_width, wm_z_max + 2){
 728     union(){
 729       WallMountMounts();
 730       WallMountBaseMounts();
 731     }
 732     union(){
 733       WallMountScrewHoles();
 734       WallMountBaseScrewsEtc();
 735     }
 736   }
 737 }
 738
 739 module WallMountBase(){ ////toplevel
 740   difference(){
 741     union(){
 742       linextr(wmbb_z_min, wmb_z_max) {
 743         difference(){
 744           for (my = [0,1]) {
 745             mirror([0, my]) {
 746               rectfromto([ -sm_outer_rad, wmbb_y_max - wmb_mount_y_width ],
 747                          [ wmbb_x_outer, wmbb_y_max ]);
 748             }
 749           }
 750           WallMountBaseRingCut();
 751         }
 752       }
 753     }
 754   }
 755 }
 756
 757 module WallMountForBaseDemo(){ ////toplevel
 758   WallMountForBase();
 759   color("blue") WallMountBase();
 760   %WallMountBaseScrewsEtc();
 761 }
 762
 763 module CatchAssemblyCoreProfile(){
 764   difference(){
 765     union(){
 766       hull(){
 767         translate(cpp3) circle(r= catch_cr3);
 768         polygon([ cpp3,
 769                   cpp2r,
 770                   cpp5,
 771                   cpph,
 772                   cppd
 773                   ]);
 774       }
 775       polygon([cppD,
 776                cppC,
 777                cpp9,
 778                cpp10,
 779                cpp11,
 780                cpp4,
 781                cpp2r,
 782                cpp2d,
 783                cppA,
 784                cppE
 785                ]);
 786       translate(cpp8) circle(r= catch_cr);
 787     }
 788     hull(){
 789       translate(cpp4) circle(r= catch_cr);
 790       translate(cpp5) circle(r= catch_cr);
 791       translate(cpp7) circle(r= catch_cr);
 792       polygon([cpp4,
 793                cppg,
 794                cpph,
 795                cpp10,
 796                cpp11,
 797                ]);
 798     }
 799     translate(cpp2) circle(r= catch_cr);
 800   }
 801   // if cpp11 is above cpp10, the subtracted hull above
 802   // can go down too far.  Ensure we do not cut off below cppy6.
 803   polygon([ cppE,
 804             cppD,
 805             cpp9,
 806             [ cpp9[0],            cppy6 ],
 807             [ cpp7[0] - catch_cr, cppy6 ],
 808             cpp2d
 809             ]);
 810 }
 811
 812 module CatchTipProfile(dy){
 813   ddy = [0,dy];
 814   intersection(){
 815     translate(cppF){
 816       difference(){
 817 //      circle(r = dist2d(cppF, cppd));
 818         //circle(r = dist2d(cppF, cppa));
 819       }
 820     }
 821     polygon([ cppa,
 822               cppi + ddy,
 823               cppd + ddy,
 824               cppc,
 825               cppb ]);
 826   }
 827 }
 828
 829 module CatchHeadProfile(){
 830   polygon([ cppd,
 831             cppd,
 832             cppi,
 833             cppf,
 834             cppe,
 835             cpph ]);
 836 }
 837
 838
 839 module CatchCore(){ /////toplevel
 840   linear_extrude(height=catch_strap_thick, convexity=10)
 841     CatchAssemblyCoreProfile();
 842
 843   hull(){
 844     linear_extrude(height=catch_head_th, convexity=10)
 845       CatchTipProfile(0);
 846     linear_extrude(height=catch_tip_th, convexity=10)
 847       CatchTipProfile(catch_tip_th - catch_head_th);
 848   }
 849
 850   linear_extrude(height=catch_head_th, convexity=10)
 851     CatchHeadProfile();
 852
 853   translate(concat(cppB,[0])) hull(){
 854     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 855       sphere(r = catch_knob_dia/2);
 856     cylinder(r = catch_knob_dia/2, h = 0.1);
 857   }
 858 }
 859
 860 module CatchPreDistort(){ /////toplevel
 861   scale(100 / sm_inner_rad)
 862     rotate([90,0,0])
 863     CatchCore();
 864 }
 865
 866 module CatchAssembly(){ /////toplevel
 867   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 868     translate([0,0, catch_assembly_dy])
 869     scale(sm_inner_rad / 100)
 870     import(str("poster-tube-lid,CatchPostDistort-fa",
 871                (coarse ? 20 : 3),
 872                ".stl"),
 873            convexity=20);
 874
 875   SomeStrap(catch_strap_width){
 876     union(){ }
 877     union(){
 878       translate([-200, -200, -200])
 879         cube([400, 200, 400]);
 880     }
 881   }
 882 }
 883
 884 module CatchDemo(){ /////toplevel
 885   color("blue") translate([0,0,
 886                            -catch_assembly_dy
 887              ])
 888     CatchAssembly();
 889   translate([0,0,+side_height
 890              ])
 891     Cover();
 892 }
 893
 894 module CatchDemoS(){ /////toplevel
 895   color("blue") translate([0,0,
 896              -catch_assembly_dy
 897              ])
 898     CatchAssembly();
 899   intersection(){
 900     translate([0,0,+side_height
 901                ])
 902       Cover();
 903     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 904   }
 905   color("black")
 906     translate([0,-33,0])
 907     cube([6.15, 2,2], center=true);
 908 }
 909
 910 module CatchPinProfileDemo(){ /////toplevel
 911   translate([0, 0 * -bayo_behind,0]) {
 912     echo("G ",
 913          bayo_n[0] - bayo_e[0]);
 914     color("blue") translate([0,0,
 915                              +1,
 916                ]) {
 917       CatchAssemblyCoreProfile();
 918       CatchHeadProfile();
 919     }
 920     translate([0,0,10])
 921       color("red")
 922       CatchTipProfile(0);
 923
 924     polygon(bayo_polygon, convexity=10);
 925
 926     // adhoc show a position
 927     color("purple")
 928     translate(concat(
 929                      cppa,
 930                      10
 931                      )) difference(){ circle(2.5); circle(2.0); }
 932
 933  }
 934 }
 935
 936 //ProfilesDemo();
 937 //BayonetCutout();
 938 //MainProfile();
 939 //Cover();
 940 //Jig();
 941 //CoverTest();