poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 // Print, for each end:
   4 //
   5 //   CoverPrint
   6 //   StrapMount
   7 //   CatchAssembly
   8 //
   9 // For attaching tube to wall, with base, for storing sticks etc.
  10 //
  11 //   WallMount             goes near top
  12 //   WallMountForBase      goes at bottom
  13 //   WallMountBase         attaches to bottom, glue some neoprene to it
  14 //   WallMountBaseCutJig   jig for cutting neoprene
  15
  16 include <funcs.scad>
  17 include <utils.scad>
  18
  19 coarse = false;
  20 enable_head_cups = false;
  21
  22 main_dia = 71.2 + 0.50 - 2.26;
  23 top_thick_middle = 4;
  24 top_thick_by_oring = 3.0;
  25 top_middle_dr = 11;
  26
  27 main_cnr = 6.0;
  28
  29 min_wall = 3;
  30
  31 rivet_posn = 6.0 + 0.30;
  32 rivet_thick = 1.67;
  33 rivet_width = 4.15 + 1.0;
  34 rivet_tall = 5.51 + 1.49;
  35
  36 over_rivet_wall = 1.0;
  37 side_rivet_gap = 1.5;
  38 inside_rivet_gap = 1.5;
  39
  40 bayo_interf = 0.30;
  41 bayo_behind = 8.5;
  42 bayo_interf_width = 2.0;
  43 bayo_interf_slope = 0.5;
  44
  45 oring_thick = 5.0;
  46 oring_bore = 62.0;
  47
  48 oring_upper_embed_angle = 80;
  49 oring_compress = 0.1; // proportion
  50 oring_compress_more = 0.2;
  51
  52 oring_rm_beside = 8;
  53 oring_rm_scale = 2.0;
  54 oring_rm_angle = 20;
  55
  56 side_taper = 1.0;
  57
  58 bayo_gap = 6.0;
  59
  60 bayo_entry = 1.167;
  61 bayo_inramp = 0.9;
  62
  63 bayo_slice_size = coarse ? 5 : 1;
  64
  65 brace_hole_width = 1.0;
  66 brace_above_below = 1.2;
  67 brace_end_shorter = 0.3;
  68
  69 jig_thick = 1.4;
  70 jig_hole_dia = 3.0;
  71 jig_rim = 5;
  72 jig_mark = 5;
  73
  74 strap_loop_thick = 6;
  75 strap_loop_inside = 10;
  76 strap_loop_strlen = 10;
  77 strap_loop_elevation = 45;
  78
  79 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
  80 sm_main_thick = 2.0;
  81 sm_main_width = 20;
  82
  83 sm_bolt_dia = 3.5 + 0.1;
  84 sm_bolt_shaft = 21.0;
  85 sm_bolt_head_dia = 6.94 + 1.0;
  86 sm_bolt_head_thick = 2.14;
  87 sm_bolt_nut_width = 5.89 + 0.25;
  88 sm_bolt_nut_thick = 3.68;
  89 sm_bolt_tighten_allow = 2.0;
  90
  91 sm_bolt_y_clear = 0.75;
  92 sm_bolt_y_over = 0.5;
  93
  94 sm_closure_cnr = 3.0;
  95
  96 wm_thick = 5;
  97 wm_screw_dia = 4.5; // Timco wood screw 40mm, use brown plug
  98 wm_screw_around = 5.0;
  99 wm_screw_slot = 3.5;
 100 wm_screw_head = 8.0;
 101
 102 wmb_screw_dia = 5;
 103 wmb_screw_head_dia = 8.7 + 0.5;
 104 wmb_screw_around_x = 4; // XXX
 105 wmb_screw_around_z = 6; // XXX
 106 wmb_screw_depth_min = 10;
 107 web_screw_len = 15 + 1; // XXX
 108 wmb_nut_across = 8; // XXX
 109 wmb_nut_around_min = 2; // XXX
 110 wmb_nut_behind_min = 5;
 111 wmb_nut_th = 4; // XXX
 112 wmb_mount_wall = 4.5;
 113 wmb_mount_gap_xy = 0.5;
 114 wmb_mount_gap_z = 0.5;
 115 wmb_mount_y_width = 10;
 116 wmb_bottom_gap = 35; // includes allowance for padding, etc.
 117 wmb_bottom_th = 7;
 118 wmb_bottom_th_min = 1;
 119 wmb_ring_gap = 1.0;
 120 wmb_base_extra_rad = 10;
 121 wmb_jig_th = 1;
 122 wmb_jig_around_gap = 1;
 123
 124 catch_stalk_h = 4.5;
 125 catch_stalk_len = 50;
 126 catch_tip_th = 4;
 127 catch_head_th = 3;
 128
 129 catch_pin_slop = 0.25; // each side, and above
 130 catch_pin_slop_x_extra = 0.0; // only on one side
 131 catch_stalk_above_gap = 1.5;
 132 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 133
 134 catch_strap_width = 12;
 135 catch_stalk_base_width = 15;
 136
 137 catch_knob_dia = 6;
 138 catch_knob_above_gap = 5;
 139 catch_knob_height = 3.0;
 140
 141 catch_stalk_below_gap = 1.0;
 142 catch_stalk_beside_gap = 2.0;
 143
 144 // calculated
 145
 146 TAU = PI*2;
 147
 148 bayo_entry_x = bayo_entry;
 149 bayo_entry_z = bayo_entry;
 150 bayo_inramp_x = bayo_inramp;
 151 bayo_inramp_z = bayo_inramp;
 152
 153 oring_mid_dia = oring_bore + oring_thick;
 154 oring_outer_dia = oring_mid_dia + oring_thick;
 155
 156 oring_oblate = (1 - oring_compress);
 157
 158 oring_y_rad = oring_thick/2 * oring_oblate;
 159 oring_x_rad = oring_thick/2 / oring_oblate;
 160
 161 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 162
 163 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 164 side_thick = rivet_tall + over_rivet_wall;
 165
 166 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 167
 168 middle_bot_z = top_z - top_thick_middle;
 169
 170 bayo_top_z = bayo_behind + bayo_gap;
 171
 172 bayo_nom_rad = main_dia/2 + side_thick;
 173 bayo_real_rad = main_dia/2 + rivet_tall;
 174
 175 rivet_entry_width = rivet_width + side_rivet_gap;
 176
 177 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 178
 179 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 180 handling_angle = 45;
 181
 182 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 183 sm_outer_rad = sm_inner_rad + sm_main_thick;
 184
 185 wm_main_width = sm_main_width;
 186 wm_screwdriver_dia = wm_screw_head;
 187 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 188                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 189 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 190 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 191 wm_lhs_y_min = -wm_y_max;
 192 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
 193 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 194 wm_y_slot1_max = wm_y_max + wm_screw_slot/2;
 195 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 196 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 197 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
 198 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 199
 200 wmb_mount_cut_rad = sm_outer_rad + wmb_ring_gap;
 201 wmb_nut_rad = wmb_nut_across / cos(30) * 0.5;
 202 wmb_x_screw_plus_around_r = max(
 203                                 wmb_screw_around_x + wmb_screw_dia/2,
 204                                 wmb_nut_around_min + wmb_nut_across/2
 205                                 );
 206 wmb_x_screw = -sm_outer_rad + wmb_x_screw_plus_around_r;
 207 wmb_x_outer = -sm_outer_rad + wmb_x_screw_plus_around_r * 2;
 208 function wmb_screw_thing_y_min(dia) = sqrt(
 209                        pow(wmb_mount_cut_rad, 2) -
 210                        pow(wmb_x_screw + dia/2, 2)
 211                        );
 212 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
 213 wmb_y_nut_min = max(
 214     wmb_screw_thing_y_min(wmb_nut_across + wmb_nut_around_min*2),
 215     wm_y_slot1_max
 216                     );
 217 wmb_y_mount_max = max(
 218                       wmb_y_nut_min + wmb_nut_th + wmb_nut_behind_min,
 219                       wmb_y_screw_end + wmb_screw_depth_min
 220                       );
 221 wmb_z_screw = max(
 222                   wmb_screw_around_z + wmb_screw_dia/2,
 223                   wmb_nut_around_min + wmb_nut_rad
 224                   );
 225 wmb_z_max = wmb_z_screw * 2;
 226 wmbb_y_max = wmb_y_mount_max + wmb_mount_gap_xy + wmb_mount_wall;
 227 wmbb_x_outer = wmb_x_outer + (wmb_mount_gap_xy + wmb_mount_wall);
 228 wmbb_z_flat_max = -wmb_bottom_gap;
 229 wmbb_z_flat_whole_min = wmbb_z_flat_max - wmb_bottom_th_min;
 230 wmbb_z_min      = wmbb_z_flat_max - wmb_bottom_th;
 231 wmbb_r_top = main_dia/2 + wmb_base_extra_rad;
 232 wmbb_r_bottom = wmbb_r_top - (wmb_bottom_th - wmb_bottom_th_min);
 233
 234 smc_pos = [ 0, sm_inner_rad, 0 ];
 235
 236 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 237 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 238
 239 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 240 smc_max_y = smc_bolt_y + sm_bolt_y_over
 241   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 242 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 243   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 244
 245 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 246 catch_strap_thick = sm_main_thick;
 247
 248 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 249
 250 $fs= coarse ? 2.5 : 0.5;
 251 $fa= coarse ? 5 : 1;
 252
 253 include <poster-tube-lid-parametric.scad>
 254
 255 // bayonet definition
 256
 257 bayo_a = [ bayo_entry_x, 0 ];
 258 bayo_p = [ 0, bayo_entry_z ];
 259 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 260 bayo_m = [ bayo_inramp_x, bayo_behind ];
 261 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 262 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 263 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 264 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 265 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 266 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 267
 268 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 269 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 270 bayo_c = bayo_d + [0,-5];
 271 bayo_b = bayo_a + [0,-5];
 272
 273 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 274
 275 bayo_polygon = [ bayo_a,
 276                  bayo_b,
 277                  bayo_c,
 278                  bayo_d,
 279                  bayo_e,
 280                  bayo_f,
 281                  bayo_g,
 282                  bayo_h,
 283                  bayo_i,
 284                  bayo_j,
 285                  bayo_k,
 286                  bayo_l,
 287                  bayo_m,
 288                  bayo_n,
 289                  bayo_p ];
 290
 291 echo(bayo_polygon);
 292
 293 // CATCH
 294
 295 cppxC = 0.41 * sm_inner_rad * TAU;
 296
 297 // catch pin
 298
 299 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 300 // radius scaling due to nom and actual radius difference in
 301 // bayo entry construction
 302
 303 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 304 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 305 cppd = [ bayo_n[0]
 306          - catch_pin_slop - catch_pin_slop_x_extra,
 307          -catch_stalk_above_gap ];
 308 cppi = [ cppa[0], cppd[1] ];
 309 cppc = [ cppd[0], cppb[1] ];
 310 cpph = cppd + [0,-1] * catch_stalk_h;
 311 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 312 cppf = [ cppa[0], cppe[1] ];
 313 cppg = [ cppa[0], cpph[1] ];
 314 cppB = 0.5 * (cppf + cppe);
 315
 316 echo("RR", sm_inner_rad / bayo_nom_rad);
 317
 318 // catch assembly depression below pin
 319
 320 cppy6 = cppB[1] - (catch_knob_dia/2
 321                    + (cppc[1] - cppd[1])
 322                    + catch_stalk_below_gap);
 323 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 324 cpp11 = cpp7 + [1,0] * catch_cr;
 325 cppy9 = cppy6 + catch_strap_width * 1/3;
 326 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 327 cpp8 = cpp9 + [0,-1] * catch_cr;
 328 cpp10 = cpp8 + [-1,0] * catch_cr;
 329 cppC = [ cppxC, cpp9[1] ];
 330 cppD = cppC + [0,-1] * catch_strap_width;
 331
 332 // catch assembly stalk and so on
 333
 334 catch_cr3 = catch_cr + catch_stalk_h;
 335
 336 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 337 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 338 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 339 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 340 cpp2r = cpp2 + [1,0] * catch_cr;
 341 cpp2d = cpp2 + [0,-1] * catch_cr;
 342 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 343 cppA = [ -cppxC, cpp9[1] ];
 344 cppE = [ cppA[0], cppD[1] ];
 345
 346 catch_assembly_dy = -cppy9 + catch_strap_width;
 347
 348
 349 module MainProfile(){
 350   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 351   difference(){
 352     union(){
 353       translate(main_cnr_pos){
 354         intersection(){
 355           difference(){
 356             circle(r = main_cnr);
 357             circle(r = main_cnr * 0.5);
 358           }
 359           square([10,10]);
 360         }
 361       }
 362       polygon([[ -top_middle_dr,        middle_bot_z      ],
 363                [ -top_middle_dr,        top_z             ],
 364                [ main_cnr_pos[0],       top_z             ],
 365                [ side_thick,            main_cnr_pos[1]   ],
 366                [ side_thick,            -side_height      ],
 367                [ side_taper,            -side_height      ],
 368                [ 0,                     -rivet_posn       ],
 369                [ 0,                     by_oring_z        ],
 370                [ -oring_x_rad,          by_oring_z        ],
 371                ],
 372               convexity=10);
 373     }
 374     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 375       hull(){
 376       translate([ 0, oring_y_rad ])
 377         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 378         circle(oring_thick/2);
 379       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 380         circle(oring_thick/2);
 381     }
 382   }
 383 }
 384
 385 module StrapLoopProfile(){
 386   circle(r = strap_loop_thick/2);
 387 }
 388
 389 module StrapLoop(){ ////toplevel
 390   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 391   extralen = strap_loop_thick * 5;
 392
 393   intersection(){
 394     rotate([strap_loop_elevation, 0,0]){
 395       for (x= [ -1, +1 ] * bigrad) {
 396         translate([x, -extralen, 0])
 397           rotate([-90,0,0])
 398           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 399                          convexity=10)
 400           StrapLoopProfile();
 401       }
 402       translate([0, strap_loop_strlen, 0]){
 403         intersection(){
 404           rotate_extrude(convexity=10)
 405             translate([bigrad, 0,0])
 406             StrapLoopProfile();
 407           translate([0,50,0])
 408             cube([100,100,100], center=true);
 409         }
 410       }
 411     }
 412     translate([0, 50, 0])
 413       cube(100, center=true);
 414   }
 415 }
 416
 417 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 418   // nom_rad > real_rad
 419   rotate([0,0, atan2(offset, nom_rad) ]){
 420     intersection(){
 421       translate([-offset, -10, 0])
 422         rotate([90,0,0])
 423         linear_extrude(height= nom_rad*2, convexity=50)
 424         children(0);
 425       translate([0,0, -25])
 426         cylinder(h=50, r= real_rad);
 427       translate([0,0, -25])
 428         linear_extrude(height= 50, convexity=50)
 429         polygon([ [ 0,0 ],
 430                   [ -slice_size, -real_rad*2 ],
 431                   [ +slice_size, -real_rad*2 ] ]);
 432     }
 433   }
 434 }
 435
 436 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 437   offs = [ for (i=[ x_min :
 438                     slice_size :
 439                     x_max + slice_size ]) i ];
 440   echo (offs);
 441   for (off=offs)
 442     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 443     children(0);
 444 }
 445
 446 module BayonetCutout(){
 447   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 448                 bayo_nom_rad,
 449                 bayo_real_rad)
 450     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 451     polygon(bayo_polygon, convexity=10);
 452 }
 453
 454 module ProfilesDemo(){ ////toplevel
 455   translate([-10,0]) MainProfile();
 456   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 457 }
 458
 459 module LimitForHandling(){ ////toplevel
 460   hull() for (r=[0,180])
 461     rotate([0,0,r]) {
 462       for (rs=[-1,+1]) {
 463         for (xd=[0,1]) {
 464           rotate([0,0, rs * handling_angle/2]) {
 465             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 466                        main_dia/2 + side_thick - main_cnr,
 467                        top_z - main_cnr]) {
 468               mirror([0,0,1])
 469                 cylinder(r= main_cnr, h=50);
 470               sphere(main_cnr);
 471             }
 472           }
 473         }
 474       }
 475     }
 476   hull() rotate_extrude(convexity=10){
 477     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 478       circle(r = main_cnr);
 479       mirror([0,1]) square([ main_cnr, 50 ]);
 480     }
 481   }
 482   //cylinder(r= handling_dia/2, h=20);
 483 }
 484
 485 module Cover(){ ////toplevel
 486   render() difference(){
 487     intersection(){
 488       union(){
 489         rotate_extrude(convexity=10)
 490           translate([main_dia/2, 0])
 491           MainProfile();
 492         translate([0,0, middle_bot_z])
 493           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 494       }
 495       LimitForHandling();
 496     }
 497     for (r=[0,180]){
 498       rotate([0,0, r])
 499         translate([0,0, -side_height])
 500         BayonetCutout();
 501       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 502         translate([0,
 503                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 504                    oring_y_rad * 1.5])
 505         rotate([-oring_rm_angle, 0, 0])
 506         mirror([0,0,1])
 507         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 508     }
 509     for (r=[0 : 60 : 179]) {
 510       rotate([0,0, r]) {
 511         height = top_thick_middle - brace_above_below*2;
 512         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 513         cube(center=true, [ oring_bore - brace_end_shorter,
 514                             brace_hole_width, height ]);
 515       }
 516     }
 517   }
 518   if (enable_head_cups)
 519     for (r=[0,180])
 520       rotate([0,0,r])
 521         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 522                    -implheadcup_large_dia * .0,
 523                    middle_bot_z + 0.1])
 524         ImplHeadCup();
 525
 526 //  translate(strap_loop_thick * [-0.5, 0, +1])
 527 //    translate([handling_dia/2, 0, -side_height])
 528 //    rotate([0,180,0]) rotate([0,0,90])
 529 //    StrapLoop();
 530 }
 531
 532 module SavingHole(){
 533   translate([0,0, -10])
 534     cylinder(r= main_dia/2 - jig_rim, h=20);
 535 }
 536
 537 module Jig(){ ////toplevel
 538   difference(){
 539     union(){
 540       translate([0,0, -side_height]){
 541         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 542       }
 543       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 544         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 545     }
 546     translate([0,0, -side_height-1])
 547       cylinder(r= main_dia/2, h= side_height + 1);
 548     SavingHole();
 549     translate([0,0, -rivet_posn])
 550       rotate([90, 0,0])
 551       translate([0,0, -100])
 552       cylinder(r= jig_hole_dia/2, h = 200);
 553   }
 554 }
 555
 556 module CoverPrint(){ ////toplevel
 557   rotate([0,180,0]) Cover();
 558 }
 559
 560 module CoverTest2(){ ////toplevel
 561   difference(){
 562     Cover();
 563     SavingHole();
 564   }
 565 }
 566
 567 module CoverTest1(){ ////toplevel
 568   difference(){
 569     CoverTest2();
 570     difference(){
 571       for (r= [ 40, 147 ]){
 572         rotate([0,0, r]){
 573           translate([0,0, -10]) {
 574             cube([ main_dia*3, main_dia * .53, 18], center=true);
 575           }
 576         }
 577       }
 578 //      translate([ 50, 0, 0 ])
 579 //      cube([ 100,
 580 //             strap_loop_inside + strap_loop_thick*2 + 1,
 581 //             100 ],
 582 //           center=true);
 583     }
 584   }
 585 }
 586
 587 module ImplHeadCupTest(){ ////toplevel
 588   for (r=[0,180])
 589     rotate([0,0,r])
 590       translate([-17,0,0])
 591       ImplHeadCup();
 592 }
 593
 594 module SomeStrap(width, cut_width=0){
 595   // children(0) is to add, (1) subtract
 596   difference(){
 597     union(){
 598       cylinder(r=sm_outer_rad, h=width);
 599       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 600                            smc_max_y,
 601                            sm_closure_cnr,
 602                            width);
 603       children(0);
 604     }
 605     translate([0,0,-1])
 606       cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
 607     translate(smc_pos)
 608       StrapMountBolt(5, width);
 609     translate(smc_pos)
 610       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 611     children(1);
 612   }
 613 }
 614
 615 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 616   // positioned relative to smc_pos
 617   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 618              smc_bolt_y,
 619              strap_width/2]){
 620     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 621       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 622     }
 623     translate([ -sm_bolt_shaft/2, 0,0 ])
 624       rotate([0,-90,0])
 625       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 626                h=smc_bolt_nut_eff_thick + l_delta);
 627     translate([ sm_bolt_shaft/2, 0,0 ])
 628       rotate([0,90,0])
 629       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 630   }
 631 }
 632
 633 module StrapMountProtrusion(half_x, max_y, cnr, width){
 634   translate(smc_pos){
 635     linear_extrude(height=width, convexity=10){
 636       hull(){
 637         for (m = [0,1]) mirror([m,0,0]) {
 638           translate([-(half_x - cnr), max_y - cnr])
 639             circle(r=cnr);
 640           translate([-half_x, -sm_inner_rad])
 641             square([1,1]);
 642         }
 643       }
 644     }
 645   }
 646 }
 647
 648 module StrapMount(){ ////toplevel
 649   SomeStrap(sm_main_width){
 650     rotate([0,0,180]){
 651       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 652                            strap_loop_thick,
 653                            sm_closure_cnr,
 654                            sm_main_width);
 655       translate(smc_pos +
 656                 [0,0, sm_main_width] +
 657                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 658         StrapLoop();
 659     }
 660     union(){ };
 661   }
 662 }
 663
 664 module WallScrewHoleSlot(){ ////toplevel
 665   ds = [-1,+1] * wm_screw_slot/2;
 666   linextr_x_yz(-(wm_thick + 1), 1) {
 667     hull(){
 668       for (d = ds)
 669         translate([d, 0])
 670           circle(r = wm_screw_dia/2);
 671     }
 672   }
 673   hull(){
 674     for (d = ds){
 675       translate([0, d, 0]){
 676         linextr_x_yz(0, 1)
 677           circle(r = wm_screw_head/2);
 678         linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
 679           circle(r = wm_screw_dia/2);
 680       }
 681     }
 682   }
 683 }
 684
 685 module WallMountMounts(){
 686   linextr(0, wm_z_max){
 687     translate([ -sm_outer_rad, 0 ])
 688       rectfromto([ 0,        wm_lhs_y_min ],
 689                  [ wm_thick, wm_y_slot1_max ]);
 690   }
 691 }
 692 module WallMountScrewHoles(){
 693   translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
 694     translate([ 0, wm_y_slotc_screw, 0 ])
 695       WallScrewHoleSlot();
 696     translate([ 0, -wm_y_slotc_screw, 0 ])
 697       rotate([90,0,0])
 698       WallScrewHoleSlot();
 699   }
 700 }
 701
 702 module WallMount(){ ////toplevel
 703   SomeStrap(sm_main_width, wm_z_max + 2){
 704     WallMountMounts();
 705     WallMountScrewHoles();
 706   }
 707 }
 708
 709 module WallMountBaseRingCut(){
 710   circle(r = wmb_mount_cut_rad);
 711 }
 712
 713 module WallMountBaseMounts(){
 714   linextr(0, wmb_z_max) {
 715     difference(){
 716       rectfromto([ -sm_outer_rad, -wmb_y_mount_max ],
 717                  [ wmb_x_outer,   +wmb_y_mount_max ]);
 718       WallMountBaseRingCut();
 719     }
 720   }
 721 }
 722
 723 // screws, nuts, slots for nuts to go down into
 724 module WallMountBaseScrewsEtc(){ ////toplevel
 725   for (my=[0,1]) {
 726     mirror([0, my, 0]) {
 727       translate([wmb_x_screw, 0, wmb_z_screw]) {
 728         linextr_y_xz(wmb_y_screw_end,
 729                      wmb_y_screw_end + 100) // XXX change 100
 730           circle(r = wmb_screw_dia/2);
 731         linextr_y_xz(wmb_y_screw_end + web_screw_len,
 732                      wmb_y_screw_end + 100) // XXX change 100
 733           circle(r = wmb_screw_head_dia/2);
 734         linextr_y_xz(wmb_y_nut_min,
 735                      wmb_y_nut_min + wmb_nut_th) {
 736           hull(){
 737             rotate(30)
 738               circle(r = wmb_nut_rad, $fn = 6);
 739             translate([0, 100]) // XXX change 100
 740               square(wmb_nut_across, center=true);
 741           }
 742         }
 743       }
 744     }
 745   }
 746 }
 747
 748 module WallMountForBase(){ ////toplevel
 749   SomeStrap(sm_main_width, wm_z_max + 2){
 750     union(){
 751       WallMountMounts();
 752       WallMountBaseMounts();
 753     }
 754     union(){
 755       WallMountScrewHoles();
 756       WallMountBaseScrewsEtc();
 757     }
 758   }
 759 }
 760
 761 module WallMountBasePillarsPlan(){
 762   for (my = [0,1]) {
 763     mirror([0, my]) {
 764       rectfromto([ -sm_outer_rad, wmbb_y_max - wmb_mount_y_width ],
 765                  [ wmbb_x_outer, wmbb_y_max ]);
 766     }
 767   }
 768 }
 769
 770 // trim parts that are would foul the wall
 771 module WallMountTrimWallFoulPlan(){
 772     translate([ -sm_outer_rad, 0])
 773     rectfromto([ -wmbb_r_top, -(wmbb_r_top + 1) ],
 774                [ 0,           +(wmbb_r_top + 1) ]);
 775 }
 776
 777 module WallMountBase(){ ////toplevel
 778   difference(){
 779     union(){
 780       // vertical blocks rising to join to wall mount
 781       linextr(wmbb_z_min, wmb_z_max) {
 782         difference(){
 783           WallMountBasePillarsPlan();
 784           WallMountBaseRingCut();
 785         }
 786       }
 787
 788       hull(){
 789         linextr(wmbb_z_flat_whole_min, wmbb_z_flat_max)
 790           circle(r = wmbb_r_top);
 791         linextr(wmbb_z_min, wmbb_z_flat_max)
 792           circle(r = wmbb_r_bottom);
 793       }
 794       linextr(wmbb_z_min, wmbb_z_flat_max) {
 795         hull(){
 796           WallMountBasePillarsPlan();
 797           circle(r = wmbb_r_bottom);
 798         }
 799       }
 800     }
 801
 802     // cutaway for mount part
 803     linextr(-wmb_mount_gap_z, wmb_z_max+1) {
 804       for (my = [0,1]) {
 805         mirror([0, my])
 806           rectfromto([ -sm_outer_rad-1, wmb_y_mount_max + wmb_mount_gap_xy ],
 807                      [ wmb_x_outer + wmb_mount_gap_xy, 1 ]);
 808       }
 809     }
 810
 811     linextr(wmbb_z_min - 1, wmb_z_max + 1)
 812       WallMountTrimWallFoulPlan();
 813     WallMountBaseScrewsEtc();
 814   }
 815 }
 816
 817 module WallMountBaseCutJigPlan(){ ////toplevel
 818   difference(){
 819     union(){
 820       circle(r = wmbb_r_top);
 821     }
 822
 823     translate([ wmb_jig_around_gap, 0 ])
 824       WallMountTrimWallFoulPlan();
 825
 826     offset(delta = wmb_jig_around_gap)
 827       WallMountBasePillarsPlan();
 828   }
 829 }
 830
 831 module WallMountBaseCutJig(){ ////toplevel
 832   translate([ 0,0, wmbb_z_flat_max + 0.5 ])
 833     linextr(0, wmb_jig_th)
 834     WallMountBaseCutJigPlan();
 835 }
 836
 837 module WallMountForBaseDemo(){ ////toplevel
 838   render() WallMountForBase();
 839   color("blue") render() WallMountBase();
 840   %WallMountBaseScrewsEtc();
 841   %WallMountBaseCutJig();
 842 }
 843
 844 module CatchAssemblyCoreProfile(){
 845   difference(){
 846     union(){
 847       hull(){
 848         translate(cpp3) circle(r= catch_cr3);
 849         polygon([ cpp3,
 850                   cpp2r,
 851                   cpp5,
 852                   cpph,
 853                   cppd
 854                   ]);
 855       }
 856       polygon([cppD,
 857                cppC,
 858                cpp9,
 859                cpp10,
 860                cpp11,
 861                cpp4,
 862                cpp2r,
 863                cpp2d,
 864                cppA,
 865                cppE
 866                ]);
 867       translate(cpp8) circle(r= catch_cr);
 868     }
 869     hull(){
 870       translate(cpp4) circle(r= catch_cr);
 871       translate(cpp5) circle(r= catch_cr);
 872       translate(cpp7) circle(r= catch_cr);
 873       polygon([cpp4,
 874                cppg,
 875                cpph,
 876                cpp10,
 877                cpp11,
 878                ]);
 879     }
 880     translate(cpp2) circle(r= catch_cr);
 881   }
 882   // if cpp11 is above cpp10, the subtracted hull above
 883   // can go down too far.  Ensure we do not cut off below cppy6.
 884   polygon([ cppE,
 885             cppD,
 886             cpp9,
 887             [ cpp9[0],            cppy6 ],
 888             [ cpp7[0] - catch_cr, cppy6 ],
 889             cpp2d
 890             ]);
 891 }
 892
 893 module CatchTipProfile(dy){
 894   ddy = [0,dy];
 895   intersection(){
 896     translate(cppF){
 897       difference(){
 898 //      circle(r = dist2d(cppF, cppd));
 899         //circle(r = dist2d(cppF, cppa));
 900       }
 901     }
 902     polygon([ cppa,
 903               cppi + ddy,
 904               cppd + ddy,
 905               cppc,
 906               cppb ]);
 907   }
 908 }
 909
 910 module CatchHeadProfile(){
 911   polygon([ cppd,
 912             cppd,
 913             cppi,
 914             cppf,
 915             cppe,
 916             cpph ]);
 917 }
 918
 919
 920 module CatchCore(){ /////toplevel
 921   linear_extrude(height=catch_strap_thick, convexity=10)
 922     CatchAssemblyCoreProfile();
 923
 924   hull(){
 925     linear_extrude(height=catch_head_th, convexity=10)
 926       CatchTipProfile(0);
 927     linear_extrude(height=catch_tip_th, convexity=10)
 928       CatchTipProfile(catch_tip_th - catch_head_th);
 929   }
 930
 931   linear_extrude(height=catch_head_th, convexity=10)
 932     CatchHeadProfile();
 933
 934   translate(concat(cppB,[0])) hull(){
 935     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 936       sphere(r = catch_knob_dia/2);
 937     cylinder(r = catch_knob_dia/2, h = 0.1);
 938   }
 939 }
 940
 941 module CatchPreDistort(){ /////toplevel
 942   scale(100 / sm_inner_rad)
 943     rotate([90,0,0])
 944     CatchCore();
 945 }
 946
 947 module CatchAssembly(){ /////toplevel
 948   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 949     translate([0,0, catch_assembly_dy])
 950     scale(sm_inner_rad / 100)
 951     import(str("poster-tube-lid,CatchPostDistort-fa",
 952                (coarse ? 20 : 3),
 953                ".stl"),
 954            convexity=20);
 955
 956   SomeStrap(catch_strap_width){
 957     union(){ }
 958     union(){
 959       translate([-200, -200, -200])
 960         cube([400, 200, 400]);
 961     }
 962   }
 963 }
 964
 965 module CatchDemo(){ /////toplevel
 966   color("blue") translate([0,0,
 967                            -catch_assembly_dy
 968              ])
 969     CatchAssembly();
 970   translate([0,0,+side_height
 971              ])
 972     Cover();
 973 }
 974
 975 module CatchDemoS(){ /////toplevel
 976   color("blue") translate([0,0,
 977              -catch_assembly_dy
 978              ])
 979     CatchAssembly();
 980   intersection(){
 981     translate([0,0,+side_height
 982                ])
 983       Cover();
 984     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 985   }
 986   color("black")
 987     translate([0,-33,0])
 988     cube([6.15, 2,2], center=true);
 989 }
 990
 991 module CatchPinProfileDemo(){ /////toplevel
 992   translate([0, 0 * -bayo_behind,0]) {
 993     echo("G ",
 994          bayo_n[0] - bayo_e[0]);
 995     color("blue") translate([0,0,
 996                              +1,
 997                ]) {
 998       CatchAssemblyCoreProfile();
 999       CatchHeadProfile();
1000     }
1001     translate([0,0,10])
1002       color("red")
1003       CatchTipProfile(0);
1004
1005     polygon(bayo_polygon, convexity=10);
1006
1007     // adhoc show a position
1008     color("purple")
1009     translate(concat(
1010                      cppa,
1011                      10
1012                      )) difference(){ circle(2.5); circle(2.0); }
1013
1014  }
1015 }
1016
1017 //ProfilesDemo();
1018 //BayonetCutout();
1019 //MainProfile();
1020 //Cover();
1021 //Jig();
1022 //CoverTest();