From fd84afa58249341881c346002eaa40a521a0d6c9 Mon Sep 17 00:00:00 2001
From: zhao <jazhawang@gmail.com>
Date: Sun, 5 Mar 2023 12:24:59 -0500
Subject: [PATCH] add/fixup hinge clearance

---
 helper/common.scad                 |  2 +-
 rack/side/hingeModule.scad         | 11 ++++++++++-
 rack/side/magnetModule.scad        |  4 +++-
 rack/side/sideWallBase.scad        |  6 +++---
 rack/side/sideWallMagnetMount.scad |  2 +-
 rack/side/sideWallVariables.scad   | 12 +++++++-----
 6 files changed, 25 insertions(+), 12 deletions(-)

diff --git a/helper/common.scad b/helper/common.scad
index 7c9714d..97d399a 100644
--- a/helper/common.scad
+++ b/helper/common.scad
@@ -4,7 +4,7 @@
 
 $fn=64;
 // TODO move these to math
-eps=0.00000001;
+eps=0.00001;
 
 inf10 = 10;
 inf50 = 50;
diff --git a/rack/side/hingeModule.scad b/rack/side/hingeModule.scad
index 694dd3a..3bc7277 100644
--- a/rack/side/hingeModule.scad
+++ b/rack/side/hingeModule.scad
@@ -4,6 +4,8 @@ include <../sharedVariables.scad>
 include <../../helper/halfspace.scad>
 include <../../helper/screws.scad>
 
+translate(v=[10,20,-2 - sideWallZHingeTotalClearance])
+*hingeModule();
 
 module hingeModule() {
 
@@ -13,7 +15,14 @@ module hingeModule() {
 
   module base() {
     intersection() {
-      cube(size = [sideWallConnW, sideWallConnD, sideWallConnLugDepression]);
+
+      union() {
+        cube(size = [sideWallConnW, sideWallConnD, sideWallConnLugDepression]);
+
+        // Riser to enforce side wall hinge clearance
+        translate(v = [0, 0, sideWallConnLugDepression])
+        cube(size = [sideWallConnW, sideWallConnD - 12, sideWallZGapClearance]);
+      }
 
       // TODO: pattern for this? beef up mirror4XY?
       cVal = 0.5;
diff --git a/rack/side/magnetModule.scad b/rack/side/magnetModule.scad
index 03bd007..5a2ce92 100644
--- a/rack/side/magnetModule.scad
+++ b/rack/side/magnetModule.scad
@@ -6,6 +6,9 @@ include <../../helper/halfspace.scad>
 include <../../misc/magnet.scad>
 include <../../helper/screws.scad>
 
+translate(v=[10,-5,-(2+sideWallZHingeTotalClearance)])
+*magnetModule();
+
 module magnetModule() {
 
   applyYBarScrewMount()
@@ -66,5 +69,4 @@ module magnetModule() {
     }
   }
 
-
 }
diff --git a/rack/side/sideWallBase.scad b/rack/side/sideWallBase.scad
index 112b91c..4851867 100644
--- a/rack/side/sideWallBase.scad
+++ b/rack/side/sideWallBase.scad
@@ -37,7 +37,7 @@ module sideWallBase() {
         roundThingHelper(sideWallX,sideWallY,sideWallZ, baseRoundness);
 
         translate(v=[sideWallThickness, sideWallThickness,0])
-        roundThingHelper(sideWallX,sideWallY - 2*sideWallThickness,sideWallZ, baseRoundness);
+        roundThingHelper(sideWallX,sideWallY - 2*sideWallThickness, sideWallZ, baseRoundness);
       }
 
       halfspace(vpos=[-1,0,0], p=[sideWallX,0,0]);
@@ -87,10 +87,10 @@ module sideWallBase() {
   module applyMagnetConnector() {
     apply_p() {
       union() {
-        translate(v = [sideWallThickness, magnetMountToYBarFront, magnetMountToYBarTop])
+        translate(v = [sideWallThickness, magnetMountToYBarFront, magnetMountToYBarTop - sideWallZHingeTotalClearance])
         sideWallMagnetMountRotated();
 
-        translate(v = [sideWallThickness, magnetMountToYBarFront, sideWallZ - magnetMountToYBarTop])
+        translate(v = [sideWallThickness, magnetMountToYBarFront, sideWallZ - (magnetMountToYBarTop- sideWallZHingeTotalClearance)])
         sideWallMagnetMountRotated();
       }
 
diff --git a/rack/side/sideWallMagnetMount.scad b/rack/side/sideWallMagnetMount.scad
index a750fae..370eb9a 100644
--- a/rack/side/sideWallMagnetMount.scad
+++ b/rack/side/sideWallMagnetMount.scad
@@ -8,7 +8,7 @@ include <../../misc/magnet.scad>
 module sideWallMagnetMount() {
   // oriented so that the xy face is the side wall's inner face
   difference() {
-    cylinder(r1 = magnetMountShellRadius+0.5, r2 = magnetMountShellRadius, h = innerSideWallToYBarMagnetConn);
+    cylinder(r1 = magnetMountShellRadius+1, r2 = magnetMountShellRadius, h = innerSideWallToYBarMagnetConn);
 
     translate(v=[0, 0, innerSideWallToYBarMagnetConn-magnetHSlacked])
     cylinder(r = magnetRSlacked, h = magnetHSlacked);
diff --git a/rack/side/sideWallVariables.scad b/rack/side/sideWallVariables.scad
index bc27d93..9dbc9cd 100644
--- a/rack/side/sideWallVariables.scad
+++ b/rack/side/sideWallVariables.scad
@@ -16,9 +16,6 @@ magnetMountShellRadius = magnetRSlacked + 1;
 
 innerSideWallToYBarMagnetConn = magnetFaceToSideWallConnOuterYEdge + sideWallSlotToOuterYEdge - sideWallThickness;
 
-magnetMountToYBarTop = magnetMountShellRadius + 1;
-magnetMountToYBarFront = magnetMountShellRadius + sideWallSlotToXZ + 2;
-
 hingePoleR = 2;
 hingePoleH = 5;
 hingeHoleR = hingePoleR + 0.2;
@@ -26,11 +23,16 @@ hingeHoleR = hingePoleR + 0.2;
 hingePoleToConnectorOuterYZFace = hingePoleR/2;
 hingePoleToConnectorOuterXZFace = hingePoleR/2;
 
-sideWallZGapClearance = 0.2;
-sideWallZ = railTotalHeight - 2*(railFootThickness + sideWallZGapClearance);
 
+sideWallZHingeSlack = 0.3;
+sideWallZGapClearance = 1.0;
+sideWallZHingeTotalClearance = sideWallZHingeSlack + sideWallZGapClearance;
+sideWallZ = (railTotalHeight - 2*railFootThickness) - 2*sideWallZHingeTotalClearance;
 sideWallY = yBarDepth;
 
+magnetMountToYBarTop = magnetMountShellRadius + sideWallZHingeTotalClearance + 1;
+magnetMountToYBarFront = magnetMountShellRadius + sideWallSlotToXZ + 2;
+
 sideWallXGapClearance = 0.2;
 sideWallX = (yBarWidth-(railTotalWidth+railSlotToInnerYEdge)) - sideWallXGapClearance;