improvements to side wall hinge

rack/side/hingeModule.scad

@@ -13,29 +13,34 @@ module hingeModule() {
   applyYBarScrewMount()
   base();
 
+  connSlack = 0.1;
+  connW = sideWallConnW - connSlack;
+  connD = sideWallConnD - connSlack;
+
   module base() {
+    translate(v=[connSlack, connSlack,0])
     intersection() {
 
       union() {
-        cube(size = [sideWallConnW, sideWallConnD, sideWallConnLugDepression]);
+        cube(size = [connW, connD, sideWallConnLugDepression]);
 
         // Riser to enforce side wall hinge clearance
         translate(v = [0, 0, sideWallConnLugDepression])
-        cube(size = [sideWallConnW, sideWallConnD - 12, sideWallZGapClearance]);
+        cube(size = [connW, connD - 12, sideWallZGapClearance]);
       }
 
       // TODO: pattern for this? beef up mirror4XY?
       cVal = 0.5;
       halfspace(p=[0,cVal,0], vpos=[0,1,1]);
       halfspace(p=[cVal,0,0], vpos=[1,0,1]);
-      halfspace(p=[sideWallConnW-cVal,0,0], vpos=[-1,0,1]);
+      halfspace(p=[connW-cVal,0,0], vpos=[-1,0,1]);
-      halfspace(p=[0,sideWallConnD-cVal,0], vpos=[0,-1,1]);
+      halfspace(p=[0,connD-cVal,0], vpos=[0,-1,1]);
     }
   }
 
   module applyHingePole() {
     apply_p() {
-      translate(v = [sideWallConnW-hingePoleR, hingePoleR, sideWallConnH])
+      translate(v = [sideWallConnW/2.0, hingePoleR, sideWallConnH])
       cylinder(r = hingePoleR, h = hingePoleH);
 
       children(0);

rack/side/magnetModule.scad

@@ -15,16 +15,22 @@ module magnetModule() {
   applyMagnetMount()
   base();
 
+  connSlack = 0.1;
+  connW = sideWallConnW - connSlack;
+  connD = sideWallConnD - connSlack;
+
   module base() {
+
+    translate(v=[connSlack, connSlack,0])
     intersection() {
-      cube(size = [sideWallConnW, sideWallConnD, sideWallConnLugDepression]);
+      cube(size = [connW, connD, sideWallConnLugDepression]);
 
       // TODO: pattern for this? beef up mirror4XY?
       cVal = 0.5;
       halfspace(p=[0,cVal,0], vpos=[0,1,1]);
       halfspace(p=[cVal,0,0], vpos=[1,0,1]);
-      halfspace(p=[sideWallConnW-cVal,0,0], vpos=[-1,0,1]);
+      halfspace(p=[connW-cVal,0,0], vpos=[-1,0,1]);
-      halfspace(p=[0,sideWallConnD-cVal,0], vpos=[0,-1,1]);
+      halfspace(p=[0,connD-cVal,0], vpos=[0,-1,1]);
     }
   }
 

rack/side/sideWallBase.scad

@@ -13,6 +13,9 @@ include <./hingeModule.scad>
 echo("Side Wall Height", sideWallZ);
 echo("Side Wall Depth", sideWallY);
 
+translate(v = [hingePoleDx ,hingePoleDy, 10])
+rotate(a=[0,0,-120])
+translate(v = [-hingePoleDx ,-hingePoleDy, 0])
 *sideWallBase();
 
 module sideWallBase() {
@@ -24,7 +27,7 @@ module sideWallBase() {
 
   module sideWallBase() {
 
-    module roundThingHelper(x,y,z,r) {
+    module sideWallShellHelper(x,y,z,r) {
       translate(v=[r, r, 0])
       minkowski() {
         cube(size = [x-r, y - 2*r, z]);
@@ -34,10 +37,10 @@ module sideWallBase() {
 
     intersection() {
       difference() {
-        roundThingHelper(sideWallX,sideWallY,sideWallZ, baseRoundness);
+        sideWallShellHelper(sideWallX,sideWallY,sideWallZ, baseRoundness);
 
         translate(v=[sideWallThickness, sideWallThickness,0])
-        roundThingHelper(sideWallX,sideWallY - 2*sideWallThickness, sideWallZ, baseRoundness);
+        sideWallShellHelper(sideWallX,sideWallY - 2*sideWallThickness, sideWallZ, baseRoundness - sideWallThickness);
       }
 
       halfspace(vpos=[-1,0,0], p=[sideWallX,0,0]);
@@ -53,32 +56,34 @@ module sideWallBase() {
     apply_pn() {
       hull() {
         hingeShell();
-        hingeBacksideProjectionPlane();
+        hingeSideProjectionPlane();
       }
 
       union() {
         hingeHole();
+
         // Trim parts of the wall for rotational clearance
-        halfspace(p=[sideWallX-5, sideWallY, 0], vpos=[1,1.5,0]);
+        halfspace(p=[0, sideWallY-2.5, 0], vpos=[-0.5,1,0]); // flat area to limit rotation against the main rail
+        halfspace(p=[sideWallX-10, sideWallY, 0], vpos=[1,2.5,0]);
       }
 
       children(0);
     }
 
     module hingeShell() {
-      translate(v = [sideWallX-hingePoleDx, sideWallY-(sideWallThickness+hingePoleDy), 0])
+      translate(v = [hingePoleDx, hingePoleDy, 0])
       cylinder(r = hingeHoleShellR, h = sideWallZ);
     }
 
     // XZ plane in line with the back of the case. Project the hinge pole shell onto this to fill any weird
     // geometries from the curves of the side wall
-    module hingeBacksideProjectionPlane() {
+    module hingeSideProjectionPlane() {
-      translate(v=[sideWallX-hingePoleDx - hingeHoleShellR,sideWallY,0])
+      translate(v=[sideWallThickness, hingePoleDy - hingeHoleShellR, 0])
-      cube(size=[2*hingeHoleShellR, eps, sideWallZ]);
+      cube(size=[eps, 2*hingeHoleShellR, sideWallZ]);
     }
 
     module hingeHole() {
-      translate(v = [sideWallX-hingePoleDx, sideWallY-(sideWallThickness+hingePoleDy), 0])
+      translate(v = [hingePoleDx , hingePoleDy, 0])
       cylinder(r = hingeHoleR, h = sideWallZ);
     }
   }

rack/side/sideWallVariables.scad

@@ -20,9 +20,6 @@ hingePoleR = 2;
 hingePoleH = 5;
 hingeHoleR = hingePoleR + 0.2;
 
-hingePoleToConnectorOuterYZFace = hingePoleR/2;
-hingePoleToConnectorOuterXZFace = hingePoleR/2;
-
 
 sideWallZHingeSlack = 0.3;
 sideWallZGapClearance = 1.0;
@@ -36,5 +33,5 @@ magnetMountToYBarFront = magnetMountShellRadius + sideWallSlotToXZ + 2;
 sideWallXGapClearance = 0.2;
 sideWallX = (yBarWidth-(railTotalWidth+railSlotToInnerYEdge)) - sideWallXGapClearance;
 
-hingePoleDx = hingePoleToConnectorOuterYZFace + sideWallSlotToOuterYEdge;
+hingePoleDx = sideWallSlotToOuterYEdge + sideWallConnW/2.0;
-hingePoleDy = hingePoleToConnectorOuterXZFace + sideWallSlotToOuterXEdge;
+hingePoleDy = sideWallY - (sideWallSlotToOuterXEdge + hingeHoleR);