incremental work

rack2/connectingBar.scad

@@ -14,7 +14,7 @@ barWidth = railSlotSpacing + railTotalWidth + sideSpacing;
 barHeight = 15;
 
 barWallThickness = 3;
-barRoundness = 12;
+barRoundness = 5;
 
 echo("Bar total depth: ", barDepth);
 echo("Bar total width: ", barWidth);
@@ -22,14 +22,13 @@ echo("Bar total width: ", barWidth);
 module connectingBar() {
 
   module positive() {
-    minkowski() {
       difference() {
         sphericalFiletEdge(barWidth, barDepth, barHeight, barRoundness);
 
-        translate(v = [barWallThickness, 40, barWallThickness])
+        translate(v = [barWallThickness, 32, barWallThickness])
-        cylindricalFiletEdge(barWidth, barDepth-80, barHeight, barRoundness);
+        cylindricalFiletEdge(barWidth, barDepth-32*2, barHeight, barRoundness);
-      }
       }
+
   }
 
   module stackConn_N() {
@@ -43,15 +42,19 @@ module connectingBar() {
   // negatives on the y-z plane to be imprinted on the side of the main
   module sideConnector_N() {
 
-    translate(v=[ - m3HeatSetInsertSlotHeightSlacked, 7, 7.5])
+    zOffset = 7.5;
+    y1 = 5;
+    y2 = 27;
+
+    translate(v=[ - m3HeatSetInsertSlotHeightSlacked, y1, zOffset])
     rotate(a=[0,90,0])
     heatSetInsertSlot_N(rackFrameScrewType);
 
-    translate(v=[ - m3HeatSetInsertSlotHeightSlacked, 35, 7.5])
+    translate(v=[ - m3HeatSetInsertSlotHeightSlacked, y2, zOffset])
     rotate(a=[0,90,0])
     heatSetInsertSlot_N(rackFrameScrewType);
 
-    translate(v=[-1, 7 + 28/2, 7.5])
+    translate(v=[-1, y1 + (y2 - y1)/2, zOffset])
     cube(size=[2,10,5], center=true);
   }
 
@@ -64,7 +67,7 @@ module connectingBar() {
       positive();
 
       union() {
-        translate(v=[10,10,0])
+        translate(v=[5,5,0])
         stackConn_N();
 
         translate(v=[barWidth - (railTotalWidth + railSlotSpacing), railSlotSpacing, barHeight - railFootThickness])
@@ -72,6 +75,10 @@ module connectingBar() {
 
         translate(v=[barWidth + eps, 0,0])
         sideConnector_N();
+
+        // TODO change this
+        translate(v=[barWidth - (railTotalWidth + railSlotSpacing) - 7, railSlotSpacing, barHeight-2])
+        cube(size=[5,13,2]);
       }
     }
 
@@ -80,10 +87,8 @@ module connectingBar() {
 }
 
 connectingBar();
-
-
 *intersection() {
   connectingBar();
 
-  cube(size=[15,100,100]);
+  cube(size=[21,100,100]);
 }

rack2/mainRail.scad

@@ -8,32 +8,29 @@ railFootThickness = 3;
 
 railTotalHeight = screwDiff * (numRailScrews + 1) + 2 * railFootThickness;
 
+railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
+railSideMountThickness = 2.5;
+
 // Distance between the middle of a screw mount and the rail's vertical edges
 railScrewHoleToInnerEdge = 5;
-railScrewHoleToOuterEdge = 5;
+railScrewHoleToOuterEdge = 7;
 
 // Distance between the midpoint of the rail screw holes.
 rackMountScrewWidth = maxUnitWidth + 2 * railScrewHoleToInnerEdge;
 
-railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
-railSideMountThickness = 2.5;
-railOtherThickness = 2.5;
-
 // Extra spacing for screws.
-frontScrewSpacing = 8;
+frontScrewSpacing = 15;
 
-sideSupportExtraSpace = 2;
+sideSupportScrewHoleToBackEdge = 4;
-sideSupportScrewHoleToFrontEdge = 5;
+sideSupportDepth = sideSupportScrewHoleToBackEdge + frontScrewSpacing;
-sideSupportScrewHoleToBackEdge = 4.5;
-sideSupportDepth = sideSupportScrewHoleToBackEdge + sideSupportScrewHoleToFrontEdge;
 
 frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
 
 railTotalWidth = frontFaceWidth;
-railTotalDepth = railFrontThickness+railOtherThickness+frontScrewSpacing+sideSupportDepth;
+railTotalDepth = railFrontThickness+sideSupportDepth;
-
 
 *mainRail();
+
 echo("Total Rail Height: ", railTotalHeight);
 
 module mainRail() {
@@ -41,19 +38,16 @@ module mainRail() {
   union() {
     _frontRailSegment();
 
-    translate(v = [0, railFrontThickness, 0])
+    translate(v = [railSideMountThickness, railFrontThickness, 0])
-    _connectingLBracketRailSegment();
-
-    translate(v = [frontFaceWidth-sideSupportExtraSpace, railFrontThickness+railOtherThickness+frontScrewSpacing, 0])
     rotate(a = [0, 0, 90])
     _sideSupportSegment();
 
+    translate(v = [0, railFrontThickness, 0]) {
 
-    translate(v = [0, railFrontThickness + railOtherThickness + frontScrewSpacing, 0]) {
+      translate(v=[railSideMountThickness,0,0])
-
       _railFeet();
 
-      translate(v = [0, 0, railTotalHeight - railFootThickness])
+      translate(v = [railSideMountThickness, 0, railTotalHeight - railFootThickness])
       _railFeet();
     }
   }
@@ -70,54 +64,40 @@ module mainRail() {
     }
   }
 
-  module _connectingLBracketRailSegment() {
-    difference() {
-      cube(size = [railOtherThickness, frontScrewSpacing + railOtherThickness, railTotalHeight]);
-
-      union() {
-        translate(v = [0, 4, railFootThickness + screwDiff / 2])
-        rotate(a = [0, 90, 0])
-        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = 10, $fn = 32, center = true);
-
-        translate(v = [0, 4, railTotalHeight - (railFootThickness + screwDiff / 2)])
-        rotate(a = [0, 90, 0])
-        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32, center = true);
-      }
-    }
-
-    translate(v = [0, frontScrewSpacing + railOtherThickness, 0])
-    rotate(a = [0, 0, 270])
-    cube(size = [railOtherThickness, frontFaceWidth - sideSupportExtraSpace, railTotalHeight]);
-  }
-
-
   module _sideSupportSegment() {
     difference() {
       cube(size = [sideSupportDepth, railSideMountThickness, railTotalHeight]);
 
+      union() {
         for (i = [1:numRailScrews]) {
-        translate(v = [sideSupportScrewHoleToFrontEdge, railFrontThickness / 2, i * screwDiff + railFootThickness])
+          translate(v = [frontScrewSpacing, railFrontThickness/2, i*screwDiff+railFootThickness])
           rotate(a = [90, 0, 0])
           cylinder(r = screwRadiusSlacked(mainRailSideMountScrewType), h = inf10, $fn = 32);
         }
-    }
 
+        translate(v = [4, 0, railFootThickness + 5])
+        rotate(a=[90,0,0])
+        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32, center = true);
+
+        translate(v = [4, 0, railTotalHeight- (railFootThickness + 5)])
+        rotate(a=[90,0,0])
+        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32, center = true);
+      }
+    }
   }
 
   module _railFeet() {
     difference() {
-      cube(size = [frontFaceWidth - sideSupportExtraSpace, sideSupportDepth, railFootThickness]);
+      cube(size = [frontFaceWidth - railSideMountThickness, sideSupportDepth, railFootThickness]);
 
-      hull() {
+      translate(v = [6, 4, 0])
-        translate(v = [1.5, 5, 0])
       cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32);
 
-        translate(v = [0, 5, 0])
+      translate(v = [6, 12, 0])
-        cube(size = [eps, screwRadiusSlacked(rackFrameScrewType) * 2, 10], center = true);
+      cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32);
-      }
-    }
-  }
 
+    }
+  }
 }
 
 module railFeetSlot_N() {
@@ -125,7 +105,10 @@ module railFeetSlot_N() {
   union() {
     cube(size = [railTotalWidth, railTotalDepth, railFootThickness]);
 
-    translate(v=[1.5, railTotalDepth - 4, -m3HeatSetInsertSlotHeightSlacked])
+    translate(v = [railSideMountThickness + 6, railFrontThickness + 4, -m3HeatSetInsertSlotHeightSlacked])
+    heatSetInsertSlot_N(rackFrameScrewType);
+
+    translate(v = [railSideMountThickness + 6, railFrontThickness + 12, -m3HeatSetInsertSlotHeightSlacked])
     heatSetInsertSlot_N(rackFrameScrewType);
   }
 }