add wip side mount l-bracket. also update mainRail with flush screws

rack-mount/side-rail/dualMount.scad

@@ -0,0 +1,91 @@
+include <../../helper/common.scad>
+include <../../helper/math.scad>
+include <../../helper/screws.scad>
+include <../../rack/config.scad>
+
+sideSupportRailBase("lBracket");
+
+module sideSupportRailBase(type) {
+
+  railLength = 100;
+  railBaseThickness = 2;
+  railBaseWidth = 18;
+  railSideThickness = 2;
+  railSideHeight = 12;
+  sideDy = -2;
+
+  frontMountPad = 10; // depends on y of box to be mounted TODO calculate this
+  sideMountPad = 10; // depends on x of box TODO calculate this
+  // distance between front and back main rail screw mounts
+  screwMountDist = 62; // TODO calculate this instead of hardcode
+  // vertical distance between local origin and main rail screw mount
+  screwMountGlobalDz = screwDiff / 2.0;
+
+
+  applyMainRailMounts()
+  sideSupportRailBaseHolder();
+
+  module sideSupportRailBaseHolder() {
+    if (type == "lBracket") {
+      sideSupportRailBaseLBracket();
+    } else {
+      error("Unsupported side support type");
+    }
+  }
+
+
+  module applyMainRailMounts() {
+
+    apply_p() {
+      translate(v=[0,frontMountPad,0])
+      union() {
+        dualMount();
+
+        translate(v=[0,screwMountDist,0])
+        dualMount();
+      }
+
+      children(0);
+    }
+  }
+
+  module dualMount() {
+
+    blockHeight = railSideHeight - sideDy;
+
+    difference() {
+      // mount block
+      translate(v = [-sideMountPad, 0, sideDy])
+      cube(size = [sideMountPad, 10, blockHeight+sideDy]);
+
+      // screw mount
+      translate(v=[-5,5,5]) // screwMountToGlobalZ
+      rotate(a=[90,0,0])
+      rotate(a=[0,90,0])
+      hexNutPocket_N(rackFrameScrewType, openSide=false);
+    }
+
+  }
+
+  module sideSupportRailBaseLBracket(backSupport=true, backThickness=3) {
+
+    translate(v=[0, 0, sideDy])
+    union() {
+      cube(size = [railBaseWidth, railLength, railBaseThickness]);
+      cube(size = [railSideThickness, railLength, railSideHeight]);
+
+      if (backSupport) {
+        translate(v=[0, railLength-backThickness, 0])
+        cube(size=[railBaseWidth, backThickness, railSideHeight]);
+      }
+    }
+  }
+
+  module sideSupportRailBaseDovetail() {}
+
+  module sideSupportRailBaseBoxed() {}
+
+}
+
+
+

rack/mainRail.scad

@@ -28,7 +28,8 @@ module mainRail() {
       translate(v = [0, railFrontThickness, 0]) {
         translate(v = [railSideMountThickness, 0, 0])
         railFeet();
-        translate(v = [railSideMountThickness, 0, railTotalHeight-railFootThickness])
+        translate(v = [railSideMountThickness, 0, railTotalHeight])
+        mirror(v=[0,0,1])
         railFeet();
       }
     }
@@ -62,8 +63,8 @@ module mainRail() {
     difference() {
       cube(size = [frontFaceWidth - railSideMountThickness, sideSupportDepth, railFootThickness]);
 
-      translate(v = [5, 4, 0])
-      cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32);
+      translate(v = [5, 4, railFootThickness])
+      counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
     }
   }
 }

stl/rack/print/xBar_P.stl

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@@ -9715,6 +9715,20 @@ solid OpenSCAD_Model
       vertex 27.5515 4.3 7.81819
     endloop
   endfacet
+  facet normal -0.51418 0 -0.857682
+    outer loop
+      vertex 27.8957 0 7.67565
+      vertex 28.0556 4.3 7.57979
+      vertex 28.0556 0 7.57979
+    endloop
+  endfacet
+  facet normal -0.51418 0 -0.857682
+    outer loop
+      vertex 28.0556 4.3 7.57979
+      vertex 27.8957 0 7.67565
+      vertex 27.8957 4.3 7.67565
+    endloop
+  endfacet
   facet normal -0.998808 0 0.0488061
     outer loop
       vertex 28.8909 0 5.81377
@@ -9897,20 +9911,6 @@ solid OpenSCAD_Model
       vertex 25.9444 0 4.42021
     endloop
   endfacet
-  facet normal -0.51418 0 -0.857682
-    outer loop
-      vertex 27.8957 0 7.67565
-      vertex 28.0556 4.3 7.57979
-      vertex 28.0556 0 7.57979
-    endloop
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-      vertex 27.8957 0 7.67565
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-    endloop
-  endfacet
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     outer loop
       vertex 28.4687 0 7.20535
@@ -15805,6 +15805,20 @@ solid OpenSCAD_Model
       vertex 27.5515 101 7.81819
     endloop
   endfacet
+  facet normal -0.51418 0 -0.857682
+    outer loop
+      vertex 27.8957 96.7 7.67565
+      vertex 28.0556 101 7.57979
+      vertex 28.0556 96.7 7.57979
+    endloop
+  endfacet
+  facet normal -0.51418 0 -0.857682
+    outer loop
+      vertex 28.0556 101 7.57979
+      vertex 27.8957 96.7 7.67565
+      vertex 27.8957 101 7.67565
+    endloop
+  endfacet
   facet normal -0.998808 0 0.0488061
     outer loop
       vertex 28.8909 96.7 5.81377
@@ -15987,20 +16001,6 @@ solid OpenSCAD_Model
       vertex 25.9444 96.7 4.42021
     endloop
   endfacet
-  facet normal -0.51418 0 -0.857682
-    outer loop
-      vertex 27.8957 96.7 7.67565
-      vertex 28.0556 101 7.57979
-      vertex 28.0556 96.7 7.57979
-    endloop
-  endfacet
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-    outer loop
-      vertex 28.0556 101 7.57979
-      vertex 27.8957 96.7 7.67565
-      vertex 27.8957 101 7.67565
-    endloop
-  endfacet
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     outer loop
       vertex 28.4687 96.7 7.20535