xaxis/carriage: Tweaks to geometry (sf1 bushings?)

use <thing_libutils/shapes.scad>;
use <thing_libutils/misc.scad>;
use <thing_libutils/transforms.scad>;
use <thing_libutils/attach.scad>;
use <thing_libutils/linear-extrusion.scad>;
use <thing_libutils/bearing.scad>
use <thing_libutils/metric-screw.scad>
use <thing_libutils/gears.scad>
include <thing_libutils/gears-data.scad>

include <config.scad>

xaxis_carriage_bearing_distance = 20*mm;
xaxis_carriage_padding = 4*mm;
xaxis_carriage_mount_distance = xaxis_carriage_bearing_distance+5*mm;
xaxis_carriage_mount_offset_z = 0*mm;
xaxis_carriage_teeth_height=xaxis_belt_width*1.5;
xaxis_carriage_mount_screws = ThreadM4;

xaxis_carriage_conn = [[0, -xaxis_bearing[1]/2 - xaxis_carriage_bearing_offset_y,0], [0,0,0]];

xaxis_carriage_beltfasten_w = 13*mm;

hobbed_gear_d_outer = 12.65*mm;
hobbed_gear_d_inner = 11.5*mm;
hobbed_gear_h = 11*mm;

gear_60t_mod05 =[
[GearMod, 0.5],
[GearTeeth, 60]
];

gear_13t_mod05 =[
[GearMod, 0.5],
[GearTeeth, 13]
];

// 13t metal gear and 60t metal gear
extruder_gear_small = gear_13t_mod05;
extruder_gear_big = gear_60t_mod05;

extruder_gears_distance=calc_gears_center_distance(gear_60t_mod05,gear_13t_mod05);
extruder_gear_small_PD = calc_gear_PD(extruder_gear_small);
extruder_gear_big_PD = calc_gear_PD(extruder_gear_big);
extruder_gear_big_OD = calc_gear_OD(extruder_gear_big);

extruder_gear_big_h = [3.85*mm, 5*mm];
extruder_motor = dict_replace_multiple(Nema17,
        [
        [NemaLengthMedium, 11.75*mm],
        [NemaFrontAxleLength, 5*mm],
        ]);

// shaft from big gear to hobbed gear
extruder_shaft_d = 5*mm;

// dist between gear and motor
extruder_gear_motor_dist = .5*mm;
extruder_motor_angle = -80;
extruder_motor_offset_x = cos(extruder_motor_angle) * extruder_gears_distance;
extruder_motor_offset_z = sin(extruder_motor_angle) * extruder_gears_distance;
extruder_motor_holedist = lookup(NemaDistanceBetweenMountingHoles, extruder_motor);

extruder_gear_big_offset=[-extruder_motor_offset_x,0,extruder_motor_offset_z];

extruder_offset = [-2,0,10*mm];
extruder_offset_a = -extruder_gear_big_offset+[
    0,
    xaxis_bearing[1] + xaxis_carriage_bearing_offset_y + .2*mm,
    0];
extruder_filapath_offset = [hobbed_gear_d_inner/2, -20*mm, 0];

extruder_hotmount_clamp_nut = MHexNutM3;
extruder_hotmount_clamp_thread = ThreadM3;

MKnurlInsertNutM3_5_42 = [
    [MHexNutHoleDia, 3*mm],
    [MHexNutWidthMin, 4.2*mm-.4*mm],
    [MHexNutThickness, 5*mm],
    [MHexNutWidthMax, 4.2*mm],
    [MHexNutThread, ThreadM3],
    [MHexNutFacets, 10],
];

MKnurlInsertNutM3_3_42 = [
    [MHexNutHoleDia, 3*mm],
    [MHexNutWidthMin, 4.2*mm-.4*mm],
    [MHexNutThickness, 3*mm],
    [MHexNutWidthMax, 4.2*mm],
    [MHexNutThread, ThreadM3],
    [MHexNutFacets, 10],
];

extruder_a_h = 15*mm;

module x_carriage(mode=undef)
{
    bottom_width = 5*mm + xaxis_bearing[2] + 2*xaxis_carriage_padding;
    top_width = 5*mm + xaxis_bearing[2]*2 + xaxis_carriage_bearing_distance + 2*xaxis_carriage_padding;
    thickness = xaxis_bearing[1]/2 + xaxis_carriage_bearing_offset_y;

    if(mode==undef)
    {
        difference()
        {
            x_carriage(mode="pos");
            x_carriage(mode="neg");
        }
    }
    else
    if(mode=="pos")
    {
        hull()
        {
            // top bearings
            translate([0,0,xaxis_rod_distance/2])
                rcubea([top_width, thickness, xaxis_bearing[1]+xaxis_carriage_padding+ziptie_bearing_distance*2], align=[0,1,0]);

            /*rcubea([top_width,thickness,xaxis_rod_distance/2], align=[0,1,0]);*/

            // bottom bearing
            translate([0,0,-xaxis_rod_distance/2])
                rcubea([bottom_width, thickness, xaxis_bearing[1]+xaxis_carriage_padding+ziptie_bearing_distance*2], align=[0,1,0]);

            /// support for extruder mount
            translate(extruder_offset)
            for(pos=extruder_b_mount_offsets)
            translate(pos)
            rcylinder(r=4*mm, align=[0,1,0], orient=[0,1,0]);

        }
        translate([0,xaxis_bearing[1]/2+xaxis_carriage_bearing_offset_y+xaxis_carriage_beltpath_offset+.1,0])
        {
            translate([0,-xaxis_beltpath_width/2,0])
                for(x=[-1,1])
                    translate([x*(xaxis_carriage_beltfasten_w/2+5),-xaxis_beltpath_width/2,xaxis_pulley_inner_d/2])
                        rcubea([xaxis_carriage_beltfasten_w,xaxis_beltpath_width,xaxis_beltpath_height/3], align=[0,0,-1]);
        }
    }
    else if(mode=="neg")
    {
        for(i=[-1,1])
        translate([
                i*(xaxis_bearing[2]/2+xaxis_carriage_bearing_distance/2),
                xaxis_bearing[1]/2+xaxis_carriage_bearing_offset_y,
                xaxis_rod_distance/2
        ])
        {
            bearing_mount_holes(xaxis_bearing, orient=[1,0,0]);
            cubea([xaxis_bearing[2]*2,xaxis_bearing[1]/2+10,xaxis_bearing[1]+1*mm], align=[0,1,0]);
        }

        translate([
                0,
                xaxis_bearing[1]/2+xaxis_carriage_bearing_offset_y,
                -xaxis_rod_distance/2])
        {
            bearing_mount_holes(xaxis_bearing, orient=[1,0,0]);
            cubea([xaxis_bearing[2]*2,xaxis_bearing[1]/2+10,xaxis_bearing[1]+1*mm], align=[0,1,0]);
        }

        translate([0,xaxis_carriage_beltpath_offset+.1,0])
        {
            translate([0,-xaxis_beltpath_width/2,0])
            {
                difference()
                {
                    rcubea([500,xaxis_beltpath_width*2,xaxis_beltpath_height], align=[0,1,0]);
                    for(x=[-1,1])
                    translate([x*(xaxis_carriage_beltfasten_w/2+5),-xaxis_beltpath_width/2,xaxis_pulley_inner_d/2])
                        rcubea([xaxis_carriage_beltfasten_w,xaxis_beltpath_width*2,xaxis_beltpath_height/3], align=[0,1,-1]);
                }
            }
        }
    }
    else if(mode=="vit")
    {
        for(x=[-1,1])
        translate([
                x*(xaxis_carriage_bearing_distance+xaxis_bearing[2])/2,
                xaxis_bearing[1]/2 + xaxis_carriage_bearing_offset_y,
                xaxis_rod_distance/2
        ])
            bearing(xaxis_bearing, orient=[1,0,0]);

        translate([
                0,
                xaxis_bearing[1]/2 + xaxis_carriage_bearing_offset_y,
                -xaxis_rod_distance/2
        ])
            bearing(xaxis_bearing, orient=[1,0,0]);

        /*translate([0,xaxis_carriage_beltpath_offset,0])*/
        /*for(i=[-1,1])*/
        /*translate([i*100,0,0])*/
        /*pulley(xaxis_idler_pulley, orient=[0,1,0]);*/
    }
}

module extruder_gear_small()
{
    difference()
    {
        union()
        {
            hull()
            {
                cylindera(d=extruder_gear_small_PD, h=7*mm, orient=[0,1,0], align=[0,1,0]);
                cylindera(d=10*mm, h= 3*mm, orient=[0,1,0], align=[0,1,0]);
            }
            cylindera(d=extruder_gear_small_PD, h=13*mm, orient=[0,1,0], align=[0,1,0]);
        }
        cylindera(d=5*mm, h=13*mm+.1, orient=[0,1,0], align=[0,1,0]);
    }
}

module extruder_gear_big(align=[0,0,0], orient=[0,0,1])
{
    total_h = extruder_gear_big_h[0]+extruder_gear_big_h[1];
    size_align([extruder_gear_big_PD, extruder_gear_big_PD, total_h], align=align, orient=orient)
    translate([0,0,-extruder_gear_big_h[0] + total_h/2])
    difference()
    {
        union()
        {
            cylindera(d=extruder_gear_big_PD, h=extruder_gear_big_h[0], orient=[0,0,1], align=[0,0,1]);
            cylindera(d=12*mm, h=extruder_gear_big_h[1], orient=[0,0,1], align=[0,0,-1]);
        }
        translate([0,0,-.5])
        cylindera(d=5*mm, h=total_h+.2, orient=[0,0,1], align=[0,0,0]);
    }
}

module extruder_a_motor_mount_cut(motor=Nema17, h=10*mm)
{
    screw_dist = lookup(NemaDistanceBetweenMountingHoles, motor);

    // round dia
    translate([0, .1, 0])
    cylindera(d=1.1*lookup(NemaRoundExtrusionDiameter, motor), h=h, orient=[0,1,0], align=[0,1,0]);

    // motor axle
    translate([0, .1, 0])
    cylindera(d=1.2*lookup(NemaAxleDiameter, motor), h=lookup(NemaFrontAxleLength, motor)+2*mm, orient=[0,1,0], align=[0,1,0]);

    // bearing for offloading force on motor shaft
    scale(1.03)
    bearing(extruder_a_bearing, override_h=h, orient=[0,1,0], align=[0,-1,0]);

    motor_thread=ThreadM3;
    motor_nut=MHexNutM3;
    for(x=[-1,1])
    for(z=[-1,1])
    translate([x*screw_dist/2, -h, z*screw_dist/2])
    {
        if(x!=-1 || z!=-1)
        {
            screw_cut(motor_nut, h=h, with_nut=false, orient=[0,1,0], align=[0,1,0]);
        }
        else
        {
            // use knurl nut for the one screw that is hidden by gear
            translate([0,h,0])
            screw_cut(nut=MKnurlInsertNutM3_5_42, h=5*mm, orient=[0,-1,0], align=[0,-1,0]);
        }
    }
}

module extruder_a(show_vitamins=false)
{
    /*if(false)*/
    difference()
    {
        hull()
        /*union()*/
        {
            side = 15*mm;
            /*rcubea([extruder_motor_holedist+side/2+5*mm,extruder_a_h,extruder_motor_holedist+side/2], align=[0,1,0]);*/
            hull()
            {
                for(x=[-1,1])
                for(z=[-1,1])
                translate([(extruder_motor_holedist/2)*x,0,(extruder_motor_holedist/2)*z])
                rotate([0,x*45,0])
                rcubea([side/2,extruder_a_h,side/2], align=[0,1,0]);
            }
            translate(extruder_gear_big_offset)
            cylindera(d=extruder_gear_big_OD+2*mm+5*mm, h=extruder_a_h, orient=[0,1,0], align=[0,-1,0], round_radius=2);
        }

        //cutout for access to small gear tightscrew
        translate([0,0,lookup(NemaSideSize, extruder_motor)/2])
        translate([0,extruder_a_h,0])
        cylindera(d=11*mm, h=lookup(NemaSideSize, extruder_motor)/2, orient=[0,0,1], align=[0,0,-1]);

        //cutout for access to big gear tightscrew
        /*translate([-lookup(NemaSideSize, extruder_motor)/2,0,0])*/
        translate(extruder_gear_big_offset)
        translate([0,extruder_gear_big_h[0],0])
        translate([0,extruder_gear_big_h[1]/2+1*mm,0])
        rotate([0,-25,0])
        cylindera(d=7*mm, h=lookup(NemaSideSize, extruder_motor)/2, orient=[1,0,0], align=[-1,0,0]);

        translate([0,extruder_a_h,0])
        {
            translate(extruder_gear_big_offset)
            {
                // big gear cutout
                translate([0,-between_bearing_and_gear,0])
                translate([0,-extruder_a_bearing[2],0])
                translate([0,-extruder_gear_big_h[1],0])
                {
                    translate([0,2*mm,0])
                    cylindera(d=extruder_gear_big_OD+2*mm, h=extruder_a_h+.2, orient=[0,1,0], align=[0,1,0]);

                    translate([0,-.1,0])
                        cylindera(d=12*mm+3*mm, h=extruder_gear_big_h[1]+.2*mm, orient=[0,1,0], align=[0,-1,0]);
                }

                translate([0,.1,0])
                cylindera(d=extruder_shaft_d+1*mm, h=extruder_a_h+.2, orient=[0,1,0], align=[0,1,0]);

                translate([0,.1,0])
                scale(1.02)
                bearing(extruder_a_bearing, extra_h=.3*mm, orient=[0,1,0], align=[0,-1,0]);
            }

            extruder_a_motor_mount_cut(extruder_motor, h=extruder_a_h+1);
        }

    }

    between_bearing_and_gear=0*mm;
    /*if(false)*/
    if(show_vitamins)
    translate([0,extruder_a_h,0])
    {
        translate([0,-extruder_gear_motor_dist,0])
        {
            extruder_gear_small();

            // big gear
            translate(extruder_gear_big_offset)
            {
                translate([0,-between_bearing_and_gear,0])
                translate([0,-extruder_a_bearing[2],0])
                extruder_gear_big(orient=[0,-1,0], align=[0,-1,0]);

                bearing(extruder_a_bearing, orient=[0,1,0], align=[0,-1,0]);

                /*translate([0,extruder_a_bearing[2],0])*/
                {
                    cylindera(h=60*mm, d=extruder_shaft_d, orient=[0,1,0], align=[0,1,0]);
                }
            }
        }
        translate([0,-1*mm,0])
        motor(extruder_motor, NemaMedium, dualAxis=false, orientation=[-90,0,0]);
    }
}

// from E3D V6 heatsink drawing
// http://wiki.e3d-online.com/wiki/File:DRAWING-V6-175-SINK.png
// each entry == dia + h
hotmount_d_h=[[16*mm,3.7*mm],[12*mm,6*mm],[16*mm,3*mm]];
hotmount_outer_size_xy=max(vec_i(hotmount_d_h,0))+5*mm;
hotmount_outer_size_h=max(vec_i(hotmount_d_h,1))+5*mm;
hotmount_offset_h=-5*mm;

// which side does hotend slide in (x-axis, i.e. -1 is left, 1 is right)
hotmount_tolerance=1.05*mm;

// hotmount clamp screws distance from center
hotmount_clamp_thread = ThreadM3;
hotmount_clamp_nut = MKnurlInsertNutM3_5_42;

hotmount_clamp_screw_dia = lookup(ThreadSize, hotmount_clamp_thread);
hotmount_clamp_screws_dist = hotmount_d_h[1][1] + 1.2*hotmount_clamp_screw_dia;
hotmount_clamp_pad = 0;
hotmount_clamp_thickness = 5*mm;
hotmount_clamp_y = 2*(hotmount_clamp_screws_dist + hotmount_clamp_screw_dia + hotmount_clamp_pad);
hotmount_clamp_height = hotmount_d_h[1][1];

module hotmount_cutout(extend_cut=false)
{
    // cutout of j-head/e3d heatsink mount
    heights=vec_i(hotmount_d_h,1);
    for(e=v_itrlen(hotmount_d_h))
    {
        hs=v_sum(heights,e-1);
        translate([0,0,-hs])
        {
            d=hotmount_d_h[e][0]*hotmount_tolerance;
            h=hotmount_d_h[e][1]*hotmount_tolerance;
            cylindera(d=d,h=h,align=[0,0,-1]);
            if(extend_cut)
            {
                cubea([extruder_b_w/2+1,d,h],align=[1,0,-1]);
            }
        }
    }
}

module hotmount_clamp()
{
    difference()
    {
        union()
        {
            translate([extruder_b_w/2, 0, 0]);
            {
                rcubea([hotmount_clamp_thickness, hotmount_clamp_y, hotmount_clamp_height], align=[-1,0,0]);
            }

            difference()
            {
                translate([extruder_b_w/2 * 1, 0, 0]);
                {
                    rcubea([extruder_b_w/2, hotmount_d_h[1][0], hotmount_clamp_height], align=[-1,0,0]);
                }

                translate([(-extruder_b_w/2 * 1) + (-0.5*1), 0, hotmount_d_h[0][1]+hotmount_d_h[1][1]/2])
                {
                    hotmount_cutout(extend_cut = false);
                }
            }

        }

        // clamp mount screw holes
        for(i=[-1,1])
        {
            translate([.1, i*hotmount_clamp_screws_dist, 0])
                rotate([0,90,0])
                cylindera(d=lookup(ThreadSize, extruder_hotmount_clamp_thread), h=hotmount_clamp_thickness+.2, align=[0,0,-1], extra_h=2, round_radius=2);
        }
    }
}

extruder_a_bearing = bearing_MR105;

extruder_b_bearing = bearing_MR105;
extruder_b_w = hobbed_gear_d_outer+15*mm;

extruder_b_mount_thick = 5*mm;

extruder_b_mount_offsets=[
    /*[extruder_filapath_offset[0]-1*(extruder_b_w/2+4*mm),0,-15*mm],*/
    /*[extruder_filapath_offset[0]+1*(extruder_b_w/2+4*mm)-5*mm,0,-25*mm],*/
    /*[extruder_filapath_offset[0]-4*mm,0,44.5*mm-15*mm]*/

    [extruder_filapath_offset[0]-1*(extruder_b_w/2+4*mm),0,-15*mm],
    [extruder_filapath_offset[0]+1*(extruder_b_w/2+4*mm),0,-15*mm],
    [extruder_filapath_offset[0]-4*mm,0,44.5*mm-15*mm]
];

module extruder_b(part=undef)
{
    if(part==undef)
    {
        difference()
        {
            extruder_b(part="pos");
            extruder_b(part="neg");
        }
    }
    else if(part=="pos")
    {
        // mount onto carriage
        hull()
        {
            for(pos=extruder_b_mount_offsets)
                translate(pos)
                    cylindera(d=extruder_b_mount_dia, h=extruder_b_mount_thick, orient=[0,1,0], align=[0,1,0], round_radius=2);

            intersection()
            {
                translate(extruder_b_capmount_offset)
                translate(-[0,extruder_b_capmount_offset[1],0])
                capmount(part);
                cubea([1000,extruder_b_mount_thick,1000], align=[0,-1,0]);
            }
        }

        translate(extruder_b_capmount_offset)
        rotate([-90,0,0])
        hull()
        {
            linear_extrude(1)
                projection()
                rotate([90,0,0])
                capmount(part);

            rotate([90,0,0])
                translate(-[0,extruder_b_capmount_offset[1],0])
                capmount(part);

            rotate([90,0,0])
                capmount(part);
        }

        hull()
        /*union()*/
        {
            // main house
            extruder_b_size=[
                hobbed_gear_d_outer+5*mm,
                abs(extruder_filapath_offset[1])+hobbed_gear_h/2+extruder_b_bearing[2]+4*mm,
                hobbed_gear_d_outer+5*mm
            ];
            /*translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])*/
            /*translate([hobbed_gear_d_inner/2,0,0])*/
            /*rcubea(extruder_b_size, align=[0,sign(extruder_filapath_offset[1]),0]);*/

            // gear support
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate([0,-hobbed_gear_h/2,0])
            {
                // hobbed gear support
                cylindera(d=hobbed_gear_d_outer+5*mm, h=abs(extruder_filapath_offset[1])+hobbed_gear_h/2, align=[0,-1,0], orient=[0,1,0], round_radius=2);

                // bearing support
                cylindera(d=extruder_b_bearing[1]+5*mm, h=extruder_b_bearing[2]+3*mm, align=[0,1,0], orient=[0,1,0], round_radius=2);
            }

            // guidler screw nuts support
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate([extruder_b_guidler_screw_offset_x, 0, extruder_b_guidler_screw_offset_h])
            {
                for(i=[-1,1])
                translate([0,i*(guidler_screws_distance),  0])
                cylindera(h=house_guidler_screw_h, d=guidler_screws_mount_d, orient=[1,0,0], round_radius=2);
            }

            // guidler mount
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate(extruder_guidler_mount_off)
            {
                cylindera(d=guidler_mount_d, h=guidler_mount_w, orient=[0,1,0]);
            }

            // hotmount support
            translate(extruder_filapath_offset)
            translate([0,0,-hobbed_gear_d_outer/2 + hotmount_offset_h])
            {
                rcubea([extruder_b_w, hotmount_outer_size_xy, hotmount_outer_size_h], align=[0,0,-1]);

                translate([0,-extruder_filapath_offset[1],0])
                    rcubea([extruder_b_w, abs(extruder_filapath_offset[1]), hotmount_outer_size_h], align=[0,-1,-1]);
            }

            /* clamp mount screw holes*/
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate([hobbed_gear_d_inner/2,0,-hobbed_gear_d_outer/2 + hotmount_offset_h])
            translate([0, 0, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
            for(x=[-1,1])
            {
                translate([x*hotmount_clamp_screws_dist, 0, 0])
                cylindera(d=lookup(ThreadSize, extruder_hotmount_clamp_thread)+6*mm, h=extruder_b_w, orient=[0,1,0]);
            }
        }

    }
    else if(part=="neg")
    {
        // mount onto carriage
        for(pos=extruder_b_mount_offsets)
        translate(pos)
        translate([0, -extruder_b_mount_thick-1*mm, 0])
        screw_cut(nut=MKnurlInsertNutM3_3_42, h=extruder_b_mount_thick, head_embed=true, nut_offset=-10, orient=[0,1,0], align=[0,1,0]);

        // guidler cutout
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        {
            guidler_w_cut = guidler_w+2*mm;
            guidler_w_cut_inner = guidler_bearing[2]+1*mm;
            guidler_w_cut_ext = 1000;
            difference()
            {
                union()
                {
                    /*hull()*/
                    {
                        /*hull()*/
                        {
                            translate([hobbed_gear_d_inner/2+3,0,0])
                            {
                                cubea([guidler_bearing[1]+1*mm,guidler_w_cut,guidler_bearing[1]*2], align=[1,0,1]);
                            }

                            // cut for guidler bearing
                            translate(extruder_guidler_mount_off)
                            translate(-[-guidler_mount_off[1],0,guidler_mount_off[2]])
                            cylindera(d=guidler_bearing[1], h=guidler_w_cut_inner, orient=[0,1,0], align=[0,0,0]);

                            // cut for guidler
                            translate(extruder_guidler_mount_off)
                            translate(-[-guidler_mount_off[1],0,guidler_mount_off[2]])
                            cylindera(d=guidler_bearing[0]*1.5+1*mm, h=guidler_w_cut, orient=[0,1,0], align=[0,0,0]);

                            // cutout pivot to make sure guidler can rotate out
                            guidler_pivot_r=pythag_hyp(abs(guidler_mount_off[1]),abs(guidler_mount_off[2]))+(guidler_bearing[1])/2;
                            translate([0,-guidler_w_cut/2,0])
                            translate(extruder_guidler_mount_off)
                            rotate([0,90,90])
                            pie_slice(guidler_pivot_r, 130, 270, guidler_w_cut);

                            translate([0,-guidler_w_cut/2,0])
                            translate(extruder_guidler_mount_off)
                            rotate([0,90,90])
                            pie_slice(guidler_pivot_r+4*mm, 125, 270, guidler_w_cut);
                        }

                        /*translate(extruder_guidler_mount_off)*/
                        /*{*/
                            /*hull()*/
                            /*for(y=[-1,1])*/
                            /*translate([0,y*guidler_mount_w/2,0])*/
                            /*{*/
                                /*cylindera(d=guidler_mount_d, h=guidler_mount_w, orient=[0,1,0], align=[0,-y,0]);*/
                                /*translate([-guidler_mount_d,0,-guidler_mount_d/2])*/
                                    /*cubea([10,(guidler_w-guidler_mount_w)/2+1*mm,10], align=[1,y,1]);*/
                            /*}*/
                        /*}*/
                    }
                    translate(extruder_guidler_mount_off)
                    {
                        cylindera(d=guidler_mount_d+3*mm, h=guidler_w_cut, orient=[0,1,0], align=[0,0,0]);

                        translate(-[0,extruder_filapath_offset[1],0])
                        translate(-[0,extruder_b_mount_thickness/2,0])
                        hull()
                        {
                            cylindera(d=guidler_screws_thread_dia+2*mm, h=guidler_w_cut_ext, orient=[0,1,0], align=[0,1,0]);
                            translate([0,0,-(guidler_screws_thread_dia+0*mm)])
                            cubea([10,guidler_w_cut_ext,100], align=[1,-1,1]);
                        }
                    }
                }
                // dont cut away the guilder mount
                translate(extruder_guidler_mount_off)
                {
                    cylindera(d=guidler_mount_d, h=guidler_mount_w, orient=[0,1,0]);
                    cubea([guidler_mount_d, guidler_mount_w, 10], align=[0,0,-1]);
                }
            }
        }

        // guidler screws cutouts
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        for(y=[-1,1])
        translate([extruder_b_guidler_screw_offset_x, y*(guidler_screws_distance), extruder_b_guidler_screw_offset_h])
        {
            r= guidler_screws_thread_dia/2 * 1.1;
            cubea([1000, r*2, r]);

            for(v=[-1,1])
                translate([0,0, v*r/2])
                    cylindera(r=r,h=1000, orient=[1,0,0]);

            // guidler screw nuts drop-in slots
            translate([0,0, -r*2])
                cubea([nut_m3[2]*1.25,nut_m3[1]+.5*mm,house_guidler_screw_h], align=[0,0,1], extrasize=[0,0,1], extrasize_align=[0,0,1]);
        }

        // guidler mount screw
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate(extruder_guidler_mount_off)
        {
            cylindera(d=lookup(ThreadSize, guidler_screws_thread), h=guidler_mount_w+.1, orient=[0,1,0]);
        }

        // cutout for hobbed gear (inner)
        cylindera(
                h=abs(extruder_filapath_offset[1])+hobbed_gear_h/2+1.1*mm,
                d=hobbed_gear_d_outer+1.5*mm,
                orient=[0,1,0],
                align=[0,1,0]
                );

        // hotmount clamp screws
        translate([hobbed_gear_d_inner/2, 0,-hobbed_gear_d_outer/2 + hotmount_offset_h])
        for(i=[-1,1])
        {
            translate([i*hotmount_clamp_screws_dist, 0, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
                screw_cut(nut=MKnurlInsertNutM3_5_42, h=1000, nut_offset=5*mm, head_embed=false, orient=[0,1,0], align=[0,-1,0]);
        }

        // filament path
        translate(extruder_filapath_offset)
        {
            // above drive gear
            cylindera(h=1000, d=filament_d+.7*mm, orient=[0,0,1], align=[0,0,1]);

            // below drive gear (into hotend)
            cylindera(h=1000, d=4*mm, orient=[0,0,1], align=[0,0,-1]);
        }

        // gear cutout
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate([0,-hobbed_gear_h/2-.5*mm,0])
        cylindera(d=extruder_b_bearing[1]+.3*mm, h=extruder_b_bearing[2]+.5*mm, align=[0,1,0], orient=[0,1,0]);

        // gear cutout
        cylindera(h=abs(extruder_filapath_offset[1])+hobbed_gear_h/2+extruder_b_bearing[2]+1*mm, d=extruder_b_bearing[1]+.1*mm, orient=[0,1,0], align=[0,1,0]);

        // extruder shaft
        /*extruder_shaft_len = 1000;*/
        extruder_shaft_len = abs(extruder_filapath_offset[1])+hobbed_gear_h/2+extruder_b_bearing[2]+1*mm;
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate([0,-extruder_filapath_offset[1]+.1,0])
        cylindera(h=extruder_shaft_len, d=extruder_shaft_d, orient=[0,1,0], align=[0,1,0]);

        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate([hobbed_gear_d_inner/2,0,-hobbed_gear_d_outer/2 + hotmount_offset_h+.01])
        rotate([0,0,-90])
        {
            hotmount_cutout(extend_cut=true);

            // clamp mount screw holes
            for(i=[-1,1])
            {
                translate([0, i*hotmount_clamp_screws_dist, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
                    cylindera(d=lookup(ThreadSize, extruder_hotmount_clamp_thread), h=extruder_b_w+1, orient=[1,0,0]);
            }

            // hotmount clamp cutout
            translate([extruder_b_w/2, 0, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
            {
                rcubea([hotmount_clamp_thickness+1.2, hotmount_clamp_y+0.2, hotmount_clamp_height+0.2], align=[-1,0,0], extrasize=[100,0,0], extrasize_align=[1,0,0]);
            }
        }

        translate(extruder_b_capmount_offset)
            capmount(part);
    }
    else if(part=="vit")
    {
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        {
            translate([hobbed_gear_d_inner/2,0,-hobbed_gear_d_outer/2 + hotmount_offset_h+.01])
            translate([0, -extruder_b_w/2 * (1), -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
            rotate([0,0,-90])
            hotmount_clamp();

            translate([0,-hobbed_gear_h/2-extruder_b_bearing[2]-.5*mm,0])
            {
                cylindera(h=extruder_a_h+extruder_offset_a[1]-extruder_filapath_offset[1], d=extruder_shaft_d, orient=[0,1,0], align=[0,-1,0]);

                bearing(extruder_b_bearing, orient=[0,1,0], align=[0,1,0]);
            }

            // hobbed gear
            cylindera(h=hobbed_gear_h, d=hobbed_gear_d_inner, orient=[0,1,0], align=[0,0,0]);
            for(y=[-1,1])
            translate([0,y*hobbed_gear_h/2,0])
            {
                cylindera(h=hobbed_gear_h/3, d=hobbed_gear_d_outer, orient=[0,1,0], align=[0,y,0]);
            }
        }
        translate(extruder_b_capmount_offset)
            capmount(part);
    }
}

// Final part
module x_carriage_withmounts(show_vitamins=false)
{
    difference()
    {
        /*hull()*/
        union()
        {
            x_carriage(mode="pos");

            // extruder A mount
            translate(extruder_offset)
            translate(extruder_offset_a)
            {
                for(x=[-1,1])
                for(z=[-1,1])
                {
                    if(x!=-1||z!=-1)
                    translate([x*extruder_motor_holedist/2,0,z*extruder_motor_holedist/2])
                        cylindera(d=extruder_b_mount_thickness, h=extruder_offset_a[1], orient=[0,1,0], align=[0,1,0], round_radius=2);
                }
            }
        }

        x_carriage(mode="neg");

        // rod between extruder part A and B
        translate(extruder_offset)
        {
            cylindera(h=100*mm, d=extruder_shaft_d+2*mm, orient=[0,1,0], align=[0,0,0]);
        }

        // extruder A mount cutout
        translate(extruder_offset)
        translate(extruder_offset_a)
        translate(-[0,extruder_offset_a[1],0])
        {
            for(x=[-1,1])
            for(z=[-1,1])
            translate([x*extruder_motor_holedist/2,0,z*extruder_motor_holedist/2])
            translate([0,.1,0])
            screw_cut(
                    nut=MHexNutM3,
                    h=extruder_offset_a[1]+.2,
                    head_embed=true,
                    with_nut=false,
                    orient=[0,1,0],
                    align=[0,1,0]
                    );
        }

        // extruder B mount cutout
        translate(extruder_offset)
        {
            for(pos=extruder_b_mount_offsets)
            translate(pos)
            screw_cut(nut=MKnurlInsertNutM3_3_42, h=5, head_embed=false, orient=[0,1,0], align=[0,1,0]);
        }
    }

    if(show_vitamins)
    {
        x_carriage(mode="vit");
    }
}

module x_extruder_hotend()
{
    hotend_conn =[[0,0,27.8-hotmount_offset_h],[0,0,1]];
    translate(extruder_filapath_offset)
    attach([[0,0,0]], hotend_conn)
        rotate([90,0,270])
        %import("stl/E3D_V6_1.75mm_Universal_HotEnd_Mockup.stl");

}

guidler_bearing = bearing_MR105;

guidler_mount_off = [0,-guidler_bearing[1]/1.8, -guidler_bearing[1]/1.4];
extruder_guidler_mount_off = [-.3*mm -guidler_mount_off[1]+hobbed_gear_d_outer/2+guidler_bearing[1]/2,0,guidler_mount_off[2]];

// length of the guidler bearing bolt/screw
guidler_mount_w=guidler_bearing[2];
guidler_mount_d=8*mm;
guidler_bolt_h=guidler_bearing[2]+4*mm;

guidler_w=max(guidler_mount_w+9*mm, guidler_bearing[2]*2.8);
guidler_d=5;
guidler_h=7;
guidler_extra_h_up=guidler_bearing[1]/2+hotmount_clamp_screw_dia/2;

guidler_screws_thread = ThreadM3;
guidler_screws_thread_dia= lookup(ThreadSize, guidler_screws_thread);
guidler_screws_distance=4*mm;
guidler_screws_mount_d = guidler_screws_thread_dia*2+5*mm;

guidler_srew_distance = 10;

house_guidler_screw_h = guidler_screws_thread_dia+10*mm;

extruder_b_guidler_screw_offset_h = 15*mm + guidler_screws_thread_dia -6*mm;
extruder_b_guidler_screw_offset_x = 2*mm;

extruder_b_mount_thickness = 10*mm;
extruder_b_mount_dia = 11*mm;

module extruder_guidler()
{
    // everything inside this module is relative to the center of the
    // bearing (that clamps the filament)
    difference()
    {
        union()
        {

            hull()
            {
                // guidler main block
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, 0])
                rcubea([guidler_w, guidler_d, guidler_h], align=[0,1,0]);

                // guidler bearing bolt holder
                cylindera(d=guidler_bearing[0]*1.5,h=guidler_w, orient=[1,0,0], round_radius=2);
            }

            hull()
            {
                // guidler main block
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, 0])
                rcubea([guidler_w, guidler_d, guidler_h], align=[0,1,0], extrasize=[0,0,guidler_extra_h_up], extrasize_align=[0,0,1]);

                // guidler mount point
                translate([0,guidler_mount_off[1], guidler_mount_off[2]])
                cylindera(d=guidler_mount_d,h=guidler_w, orient=[1,0,0], round_radius=2);
            }

            hull()
            {
                // guidler main block
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, guidler_h])
                rcubea([guidler_w, guidler_d, 1], align=[0,1,0]);

                // guidler screws mount
                for(i=[-1,1])
                translate([i*(guidler_screws_distance),guidler_mount_off[1]-guidler_mount_d/2, extruder_b_guidler_screw_offset_h])
                cylindera(r=guidler_screws_thread_dia/2*3,h=guidler_d, align=[0,-1,0], orient=[0,1,0], round_radius=2);

                // tab above screw mount, for easier open
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, extruder_b_guidler_screw_offset_h+guidler_screws_thread_dia/2*3])
                cylindera(r=5*mm,h=guidler_d/2, align=[0,-1,0], orient=[0,1,0], round_radius=2);

            }
        }

        // cutouts for clamping screws
        for(i=[-1,1])
        translate([i*(guidler_screws_distance),guidler_mount_off[1]-guidler_mount_d/2, extruder_b_guidler_screw_offset_h])
        {
            r= guidler_screws_thread_dia/2*1.1;
            translate([0, -0.1, 0])
            {
                cubea([r*2,guidler_d+.2,r], align=[0,1,0]);
                for(v=[-1,1])
                translate([0, 0, v*r/2])
                {
                    cylindera(r=r,h=guidler_d+.2, align=[0,-1,0], orient=[0,1,0]);
                }
            }

        }

        // port hole to see bearing
        translate([0,-guidler_bearing[1]/2,0])
        cubea([guidler_bearing[0]*1.1, 100, guidler_bearing[1]/2], align=[0,0,1]);

        // cutout middle mount point pivot
        translate([0,guidler_mount_off[1], guidler_mount_off[2]])
        cylindera(d=guidler_mount_d+2*mm,h=guidler_mount_w+1*mm, orient=[1,0,0]);

        // mount bolt hole
        translate([0,guidler_mount_off[1], guidler_mount_off[2]])
        cylindera(d=lookup(ThreadSize, guidler_screws_thread),h=100, orient=[1,0,0]);

        // guidler bearing bolt holder cutout
        union()
        {
            cubea([guidler_bolt_h*1.05+2*e,guidler_bearing[0]*1.05,guidler_bearing[0]*1.05],align=[0,1,0]);

            cylindera(d=guidler_bearing[0]*1.05, h=guidler_bolt_h*1.05, orient=[1,0,0]);
        }

        // guidler bearing cutout
        cylindera(d=guidler_bearing[1]*1.1, h=guidler_bearing[2]*1.1, orient=[1,0,0]);

    }

    if(show_extras)
    {
        cylindera(d=guidler_bearing[1], h=guidler_bearing[2], orient=[1,0,0]);
        cylindera(d=guidler_bearing[0], h=guidler_bolt_h, orient=[1,0,0]);
    }
}

module capmount(part=undef, height=10,thickness=5,screws_spacing=21,screw_offset=[1,0],screws_diameter=4,sensor_spacing=3,sensor_height=[15,40,5],sensor_diameter=12)
{
    align=[0,-1,0];

    OD_cut = 0*mm;
    OD = sensor_diameter+2*thickness;
    h_ = height;
    sensor_h = v_sum(sensor_height,2);

    size_align(size=[OD,OD-2*OD_cut,h_], align=align, orient=[0,0,1])
    {

        if(part == "pos")
        {
            //Sensor mount
            cylindera(d=OD, h=h_);
            cubea([OD,OD/2,h_], align=[0,1,0]);
        }

        else if(part == "neg")
        {
            translate([0,0,h_/2])
            cylindera(d=OD+1*mm, h=sensor_h, align=[0,0,1]);

            cylindera(d=sensor_diameter+0,5, h=h_+.2);

            translate([0,0,-h_/2])
            cylindera(d=OD+1*mm, h=sensor_h, align=[0,0,-1]);

            for(y=[-1,1])
                translate([0,y*OD/2, 0])
                    cubea([sensor_diameter+thickness*2,OD_cut,h_+2*e],[0,-y,0]);
        }
        else if(part == "vit")
        {
            translate([0,0,sensor_h/2])
            {
                for(e=v_itrlen(sensor_height))
                {
                    hs=v_sum(sensor_height,e-1);
                    translate([0,0,-hs])
                        if(e==0||e==2)
                            color([0.3,.4,0])
                                cylindera(d=sensor_diameter,h=sensor_height[e], align=[0,0,-1]);
                        else
                            cylindera(d=sensor_diameter,h=sensor_height[e], align=[0,0,-1]);
                }
            }
        }
    }
}

module e3d_heatsink_duct()
{
    hotend_heatsink_diameter = 25;
    hotend_heatsink_height = 32;
    hotend_heatsink_offset = 16; // offset off bottom of body that heatsink starts

    length = 55;
    width = 40;
    height = hotend_heatsink_offset+hotend_heatsink_height;

    fan_hole_dist = 32;
    m3_hexnut_dia = 6.4;
    m3_hexnut_flat_dia = 5.54;
    m3_hexnut_thickness = 2.4;

    difference() {
        union() {
            //cube([length, width, hotend_heatsink_offset+hotend_heatsink_height]);
            hull() {
                translate([0,0,20]) cube([20,40,height-20]);
                translate([50,5+17.5,height/2+20/2]) cube([5,30,height-20],center=true);
                translate([1,20,20]) rotate([0, 90, 0]) cylinder(r=38/2,h=1,center=true);
            }
        }

        // hotend heatsink hole
        translate([50, 5+17.75, hotend_heatsink_offset]) cylinder(r=hotend_heatsink_diameter/2, hotend_heatsink_height+1);
        translate([50, 5+17.75, 0]) cylinder(r=25/2, hotend_heatsink_offset+1);

        // first portion of fan duct
        difference() {
            hull() {
                translate([-1,20,20]) rotate([0, 90, 0]) cylinder(r=35/2,h=1,center=true);
                translate([50,5+17.5,24+25/2]) cube([20,20,20],center=true);
            }
            /*// support material ribs*/
            /*translate([0,12,0]) cube([length, 1, height]);*/
            /*translate([0,18,0]) cube([length, 1, height]);*/
            /*translate([0,23,0]) cube([length, 1, height]);*/
            /*translate([0,28,0]) cube([length, 1, height]);*/
        }

        // m3 traps for fan
        for (end = [-1,1]) {
            translate([-1,20+end*fan_hole_dist/2,20+fan_hole_dist/2]) rotate([0,90,0]) cylinder(r=1.6,h=30,center=true, $fn=7);
            translate([5,20+end*fan_hole_dist/2,20+fan_hole_dist/2]) rotate([0,90,0]) rotate([0,0,30]) cylinder(r=m3_hexnut_dia/2,h=m3_hexnut_thickness,center=true,$fn=6);
            translate([5-m3_hexnut_thickness/2,20+end*fan_hole_dist/2,20+fan_hole_dist/2]) rotate([end*-90,0,0]) translate([0,-m3_hexnut_flat_dia/2,0]) cube([m3_hexnut_thickness,m3_hexnut_flat_dia,10]);
        }

        if (1) {
            // clearance existing fan mounts
            cube([10,width,8]);

            // hole for clearance for wingnuts
            //translate([10,0,0]) cube([length-10,width+1,10]);

            translate([25, 5+17.75, 9]) cylinder(r=2.5, h=5, center=true);

        }
        else
        {
            // whatever. just get rid of everything for the bottom whatever mm
            //translate([-1,-1,-1]) cube([length+2,width+2,18+1]);
        }

        // clearance for bearing holder
        translate([18,0,0]) cube([40,5,25]);
        translate([10-3,0,0]) cube([50,9,6.5]);

        // TODO; clearance for extruder mounting bolt
    }
}

// flip for printing
/*e3d_heatsink_duct();*/

// extruder guidler mount point
extruder_conn_guidler = [ extruder_guidler_mount_off, [0,1,0]];

// guidler connection point
extruder_guidler_conn_mount = [ guidler_mount_off,  [1,0,0]];
extruder_guidler_roll = 45;

    if(false)
attach(extruder_conn_guidler, extruder_guidler_conn_mount, extruder_guidler_roll)
{
    extruder_guidler(show_extras=true);
}

if(false)
extruder_a(show_vitamins=true);

alpha = 0.7;
/*alpha = 1;*/
color_xcarriage = [0.3,0.5,0.3, alpha];
color_hotend = [0.8,0.4,0.4, alpha];
color_extruder = [0.2,0.6,0.9, alpha];
color_guidler = [0.4,0.5,0.8, alpha];
color_filament = [0,0,0, alpha];

extruder_b_capmount_offset=[35,-7,-41];

module x_carriage_full()
{
    color(color_xcarriage)
    x_carriage_withmounts(show_vitamins=true);

    translate(extruder_offset)
    {
        color(color_extruder)
        translate(extruder_offset_a)
        extruder_a(show_vitamins=true);

        color(color_extruder)
        {
            difference()
            {
                extruder_b(part="pos");

                extruder_b(part="neg");
            }
        }
        extruder_b(part="vit");

        color(color_guidler)
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        attach(extruder_conn_guidler, extruder_guidler_conn_mount, extruder_guidler_roll)
        {
            extruder_guidler(show_extras=true);
        }

        translate([-95,53,20])
        rotate([-152,0,0])
        import("stl/E3D_40_mm_Duct.stl");

        translate([-123.5,78.5,-54])
        rotate([0,0,-90])
        import("stl/E3D_30_mm_Duct.stl");

        color(color_hotend)
        x_extruder_hotend();

        //filament path
        color(color_filament)
        translate(extruder_filapath_offset)
        cylindera(h=1000, d=1.75*mm, orient=[0,0,1], align=[0,0,0]);
    }
}

if(false)
{
    /*rotate([90,0,0])*/
    /*x_carriage_withmounts(show_vitamins=false);*/

    /*rotate([-90,0,0])*/
    /*extruder_a();*/

    /*rotate([-90,0,0])*/
    /*extruder_b();*/

    guidler_conn_layflat = [ [0, guidler_mount_off[1]-guidler_mount_d/2, guidler_mount_off[2]],  [0,-1,0]];
    attach([[0*mm,0*mm,0],[0,0,-1]], guidler_conn_layflat)
    {
        extruder_guidler(show_extras=false);
    }

    /*hotmount_clamp();*/
}

use <thing_libutils/shapes.scad>;
use <thing_libutils/misc.scad>;
use <thing_libutils/transforms.scad>;
use <thing_libutils/attach.scad>;
use <thing_libutils/linear-extrusion.scad>;
use <thing_libutils/bearing.scad>
use <thing_libutils/metric-screw.scad>
use <thing_libutils/gears.scad>
include <thing_libutils/gears-data.scad>

include <config.scad>

xaxis_carriage_bearing_distance = 8*mm;
xaxis_carriage_padding = 4*mm;
xaxis_carriage_mount_distance = 23*mm;
xaxis_carriage_mount_offset_z = 0*mm;
xaxis_carriage_teeth_height=xaxis_belt_width*1.5;
xaxis_carriage_mount_screws = ThreadM4;

xaxis_carriage_conn = [[0, -xaxis_bearing[1]/2 - xaxis_carriage_bearing_offset_y,0], [0,0,0]];

xaxis_carriage_beltfasten_w = 20*mm;

hobbed_gear_d_outer = 12.65*mm;
hobbed_gear_d_inner = 11.5*mm;
hobbed_gear_h = 11*mm;

gear_60t_mod05 =[
[GearMod, 0.5],
[GearTeeth, 60]
];

gear_13t_mod05 =[
[GearMod, 0.5],
[GearTeeth, 13]
];

// 13t metal gear and 60t metal gear
extruder_gear_small = gear_13t_mod05;
extruder_gear_big = gear_60t_mod05;

extruder_gears_distance=calc_gears_center_distance(gear_60t_mod05,gear_13t_mod05);
extruder_gear_small_PD = calc_gear_PD(extruder_gear_small);
extruder_gear_big_PD = calc_gear_PD(extruder_gear_big);
extruder_gear_big_OD = calc_gear_OD(extruder_gear_big);

extruder_gear_big_h = [3.85*mm, 5*mm];
extruder_motor = dict_replace_multiple(Nema17,
        [
        [NemaLengthMedium, 11.75*mm],
        [NemaFrontAxleLength, 5*mm],
        ]);

// shaft from big gear to hobbed gear
extruder_shaft_d = 5*mm;

// dist between gear and motor
extruder_gear_motor_dist = .5*mm;
extruder_motor_angle = -80;
extruder_motor_offset_x = cos(extruder_motor_angle) * extruder_gears_distance;
extruder_motor_offset_z = sin(extruder_motor_angle) * extruder_gears_distance;
extruder_motor_holedist = lookup(NemaDistanceBetweenMountingHoles, extruder_motor);

extruder_gear_big_offset=[-extruder_motor_offset_x,0,extruder_motor_offset_z];

extruder_offset = [-2,0,10*mm];
extruder_offset_a = -extruder_gear_big_offset+[
    0,
    xaxis_bearing[1] + xaxis_carriage_bearing_offset_y + .2*mm,
    0];
extruder_filapath_offset = [hobbed_gear_d_inner/2, -20*mm, 0];

extruder_hotmount_clamp_nut = MHexNutM3;
extruder_hotmount_clamp_thread = ThreadM3;

MKnurlInsertNutM3_5_42 = [
    [MHexNutHoleDia, 3*mm],
    [MHexNutWidthMin, 4.2*mm-.4*mm],
    [MHexNutThickness, 5*mm],
    [MHexNutWidthMax, 4.2*mm],
    [MHexNutThread, ThreadM3],
    [MHexNutFacets, 10],
];

MKnurlInsertNutM3_3_42 = [
    [MHexNutHoleDia, 3*mm],
    [MHexNutWidthMin, 4.2*mm-.4*mm],
    [MHexNutThickness, 3*mm],
    [MHexNutWidthMax, 4.2*mm],
    [MHexNutThread, ThreadM3],
    [MHexNutFacets, 10],
];

extruder_a_h = 15*mm;

module x_carriage(mode=undef)
{
    bottom_width = xaxis_bearing[2] + 2*xaxis_carriage_padding;
    top_width = xaxis_bearing[2]*2 + xaxis_carriage_bearing_distance + 2*xaxis_carriage_padding;
    thickness = xaxis_bearing[1]/2 + xaxis_carriage_bearing_offset_y;

    if(mode==undef)
    {
        difference()
        {
            x_carriage(mode="pos");
            x_carriage(mode="neg");
        }
    }
    else
    if(mode=="pos")
    {
        hull()
        {
            // top bearings
            translate([0,0,xaxis_rod_distance/2])
                rcubea([top_width, thickness, xaxis_bearing[1]+xaxis_carriage_padding+ziptie_bearing_distance*2], align=[0,1,0]);

            /*rcubea([top_width,thickness,xaxis_rod_distance/2], align=[0,1,0]);*/

            // bottom bearing
            translate([0,0,-xaxis_rod_distance/2])
                rcubea([bottom_width, thickness, xaxis_bearing[1]+xaxis_carriage_padding+ziptie_bearing_distance*2], align=[0,1,0]);

            /// support for extruder mount
            translate(extruder_offset)
            for(pos=extruder_b_mount_offsets)
            translate(pos)
            /*translate([0, -extruder_b_mount_thick-1*mm, 0])*/
            rcylinder(r=5*mm, align=[0,1,0], orient=[0,1,0]);

        }
        translate([0,xaxis_bearing[1]/2+xaxis_carriage_bearing_offset_y+xaxis_carriage_beltpath_offset+.1,0])
        {
            translate([0,-xaxis_beltpath_width/2,0])
                for(x=[-1,1])
                    translate([x*(xaxis_carriage_beltfasten_w/2+5),-xaxis_beltpath_width/2,xaxis_pulley_inner_d/2])
                        rcubea([xaxis_carriage_beltfasten_w,xaxis_beltpath_width,xaxis_beltpath_height/3], align=[0,0,-1]);
        }
    }
    else if(mode=="neg")
    {
        for(i=[-1,1])
        translate([
                i*(xaxis_bearing[2]/2+xaxis_carriage_bearing_distance/2),
                xaxis_bearing[1]/2+xaxis_carriage_bearing_offset_y,
                xaxis_rod_distance/2
        ])
        {
            bearing_mount_holes(xaxis_bearing, orient=[1,0,0]);
            cubea([xaxis_bearing[2]*2,xaxis_bearing[1]/2+10,xaxis_bearing[1]+1*mm], align=[0,1,0]);
        }

        translate([
                0,
                xaxis_bearing[1]/2+xaxis_carriage_bearing_offset_y,
                -xaxis_rod_distance/2])
        {
            bearing_mount_holes(xaxis_bearing, orient=[1,0,0]);
            cubea([xaxis_bearing[2]*2,xaxis_bearing[1]/2+10,xaxis_bearing[1]+1*mm], align=[0,1,0]);
        }

        translate([0,xaxis_carriage_beltpath_offset+.1,0])
        {
            translate([0,-xaxis_beltpath_width/2,0])
            {
                difference()
                {
                    rcubea([500,xaxis_beltpath_width*2,xaxis_beltpath_height], align=[0,1,0]);
                    for(x=[-1,1])
                    translate([x*(xaxis_carriage_beltfasten_w/2+5),-xaxis_beltpath_width/2,xaxis_pulley_inner_d/2])
                        rcubea([xaxis_carriage_beltfasten_w,xaxis_beltpath_width*2,xaxis_beltpath_height/3], align=[0,1,-1]);
                }
            }
        }
    }
    else if(mode=="vit")
    {
        for(x=[-1,1])
        translate([
                x*(xaxis_carriage_bearing_distance+xaxis_bearing[2])/2,
                xaxis_bearing[1]/2 + xaxis_carriage_bearing_offset_y,
                xaxis_rod_distance/2
        ])
            bearing(xaxis_bearing, orient=[1,0,0]);

        translate([
                0,
                xaxis_bearing[1]/2 + xaxis_carriage_bearing_offset_y,
                -xaxis_rod_distance/2
        ])
            bearing(xaxis_bearing, orient=[1,0,0]);

        /*translate([0,xaxis_carriage_beltpath_offset,0])*/
        /*for(i=[-1,1])*/
        /*translate([i*100,0,0])*/
        /*pulley(xaxis_idler_pulley, orient=[0,1,0]);*/
    }
}

module extruder_gear_small()
{
    difference()
    {
        union()
        {
            hull()
            {
                cylindera(d=extruder_gear_small_PD, h=7*mm, orient=[0,1,0], align=[0,1,0]);
                cylindera(d=10*mm, h= 3*mm, orient=[0,1,0], align=[0,1,0]);
            }
            cylindera(d=extruder_gear_small_PD, h=13*mm, orient=[0,1,0], align=[0,1,0]);
        }
        cylindera(d=5*mm, h=13*mm+.1, orient=[0,1,0], align=[0,1,0]);
    }
}

module extruder_gear_big(align=[0,0,0], orient=[0,0,1])
{
    total_h = extruder_gear_big_h[0]+extruder_gear_big_h[1];
    size_align([extruder_gear_big_PD, extruder_gear_big_PD, total_h], align=align, orient=orient)
    translate([0,0,-extruder_gear_big_h[0] + total_h/2])
    difference()
    {
        union()
        {
            cylindera(d=extruder_gear_big_PD, h=extruder_gear_big_h[0], orient=[0,0,1], align=[0,0,1]);
            cylindera(d=12*mm, h=extruder_gear_big_h[1], orient=[0,0,1], align=[0,0,-1]);
        }
        translate([0,0,-.5])
        cylindera(d=5*mm, h=total_h+.2, orient=[0,0,1], align=[0,0,0]);
    }
}

module extruder_a_motor_mount_cut(motor=Nema17, h=10*mm)
{
    screw_dist = lookup(NemaDistanceBetweenMountingHoles, motor);

    // round dia
    translate([0, .1, 0])
    cylindera(d=1.1*lookup(NemaRoundExtrusionDiameter, motor), h=h, orient=[0,1,0], align=[0,1,0]);

    // motor axle
    translate([0, .1, 0])
    cylindera(d=1.2*lookup(NemaAxleDiameter, motor), h=lookup(NemaFrontAxleLength, motor)+2*mm, orient=[0,1,0], align=[0,1,0]);

    // bearing for offloading force on motor shaft
    scale(1.03)
    bearing(extruder_a_bearing, override_h=h, orient=[0,1,0], align=[0,-1,0]);

    motor_thread=ThreadM3;
    motor_nut=MHexNutM3;
    for(x=[-1,1])
    for(z=[-1,1])
    translate([x*screw_dist/2, -h, z*screw_dist/2])
    {
        if(x!=-1 || z!=-1)
        {
            screw_cut(motor_nut, h=h, with_nut=false, orient=[0,1,0], align=[0,1,0]);
        }
        else
        {
            // use knurl nut for the one screw that is hidden by gear
            translate([0,h,0])
            screw_cut(nut=MKnurlInsertNutM3_5_42, h=5*mm, orient=[0,-1,0], align=[0,-1,0]);
        }
    }
}

module extruder_a(show_vitamins=false)
{
    /*if(false)*/
    difference()
    {
        hull()
        /*union()*/
        {
            side = 15*mm;
            /*rcubea([extruder_motor_holedist+side/2+5*mm,extruder_a_h,extruder_motor_holedist+side/2], align=[0,1,0]);*/
            hull()
            {
                for(x=[-1,1])
                for(z=[-1,1])
                translate([(extruder_motor_holedist/2)*x,0,(extruder_motor_holedist/2)*z])
                rotate([0,x*45,0])
                rcubea([side/2,extruder_a_h,side/2], align=[0,1,0]);
            }
            translate(extruder_gear_big_offset)
            cylindera(d=extruder_gear_big_OD+2*mm+5*mm, h=extruder_a_h, orient=[0,1,0], align=[0,-1,0], round_radius=2);
        }

        //cutout for access to small gear tightscrew
        translate([0,0,lookup(NemaSideSize, extruder_motor)/2])
        translate([0,extruder_a_h,0])
        cylindera(d=11*mm, h=lookup(NemaSideSize, extruder_motor)/2, orient=[0,0,1], align=[0,0,-1]);

        //cutout for access to big gear tightscrew
        /*translate([-lookup(NemaSideSize, extruder_motor)/2,0,0])*/
        translate(extruder_gear_big_offset)
        translate([0,extruder_gear_big_h[0],0])
        translate([0,extruder_gear_big_h[1]/2+1*mm,0])
        rotate([0,-25,0])
        cylindera(d=7*mm, h=lookup(NemaSideSize, extruder_motor)/2, orient=[1,0,0], align=[-1,0,0]);

        translate([0,extruder_a_h,0])
        {
            translate(extruder_gear_big_offset)
            {
                // big gear cutout
                translate([0,-between_bearing_and_gear,0])
                translate([0,-extruder_a_bearing[2],0])
                translate([0,-extruder_gear_big_h[1],0])
                {
                    translate([0,2*mm,0])
                    cylindera(d=extruder_gear_big_OD+2*mm, h=extruder_a_h+.2, orient=[0,1,0], align=[0,1,0]);

                    translate([0,-.1,0])
                        cylindera(d=12*mm+3*mm, h=extruder_gear_big_h[1]+.2*mm, orient=[0,1,0], align=[0,-1,0]);
                }

                translate([0,.1,0])
                cylindera(d=extruder_shaft_d+1*mm, h=extruder_a_h+.2, orient=[0,1,0], align=[0,1,0]);

                translate([0,.1,0])
                scale(1.02)
                bearing(extruder_a_bearing, extra_h=.3*mm, orient=[0,1,0], align=[0,-1,0]);
            }

            extruder_a_motor_mount_cut(extruder_motor, h=extruder_a_h+1);
        }

    }

    between_bearing_and_gear=0*mm;
    /*if(false)*/
    if(show_vitamins)
    translate([0,extruder_a_h,0])
    {
        translate([0,-extruder_gear_motor_dist,0])
        {
            extruder_gear_small();

            // big gear
            translate(extruder_gear_big_offset)
            {
                translate([0,-between_bearing_and_gear,0])
                translate([0,-extruder_a_bearing[2],0])
                extruder_gear_big(orient=[0,-1,0], align=[0,-1,0]);

                bearing(extruder_a_bearing, orient=[0,1,0], align=[0,-1,0]);

                /*translate([0,extruder_a_bearing[2],0])*/
                {
                    cylindera(h=60*mm, d=extruder_shaft_d, orient=[0,1,0], align=[0,1,0]);
                }
            }
        }
        translate([0,-1*mm,0])
        motor(extruder_motor, NemaMedium, dualAxis=false, orientation=[-90,0,0]);
    }
}

// from E3D V6 heatsink drawing
// http://wiki.e3d-online.com/wiki/File:DRAWING-V6-175-SINK.png
// each entry == dia + h
hotmount_d_h=[[16*mm,3.7*mm],[12*mm,6*mm],[16*mm,3*mm]];
hotmount_outer_size_xy=max(vec_i(hotmount_d_h,0))+5*mm;
hotmount_outer_size_h=max(vec_i(hotmount_d_h,1))+5*mm;
hotmount_offset_h=-5*mm;

// which side does hotend slide in (x-axis, i.e. -1 is left, 1 is right)
hotmount_tolerance=1.05*mm;

// hotmount clamp screws distance from center
hotmount_clamp_thread = ThreadM3;
hotmount_clamp_nut = MKnurlInsertNutM3_5_42;

hotmount_clamp_screw_dia = lookup(ThreadSize, hotmount_clamp_thread);
hotmount_clamp_screws_dist = hotmount_d_h[1][1] + 1.2*hotmount_clamp_screw_dia;
hotmount_clamp_pad = 0;
hotmount_clamp_thickness = 5*mm;
hotmount_clamp_y = 2*(hotmount_clamp_screws_dist + hotmount_clamp_screw_dia + hotmount_clamp_pad);
hotmount_clamp_height = hotmount_d_h[1][1];

module hotmount_cutout(extend_cut=false)
{
    // cutout of j-head/e3d heatsink mount
    heights=vec_i(hotmount_d_h,1);
    for(e=v_itrlen(hotmount_d_h))
    {
        hs=v_sum(heights,e-1);
        translate([0,0,-hs])
        {
            d=hotmount_d_h[e][0]*hotmount_tolerance;
            h=hotmount_d_h[e][1]*hotmount_tolerance;
            cylindera(d=d,h=h,align=[0,0,-1]);
            if(extend_cut)
            {
                cubea([extruder_b_w/2+1,d,h],align=[1,0,-1]);
            }
        }
    }
}

module hotmount_clamp()
{
    difference()
    {
        union()
        {
            translate([extruder_b_w/2, 0, 0]);
            {
                rcubea([hotmount_clamp_thickness, hotmount_clamp_y, hotmount_clamp_height], align=[-1,0,0]);
            }

            difference()
            {
                translate([extruder_b_w/2 * 1, 0, 0]);
                {
                    rcubea([extruder_b_w/2, hotmount_d_h[1][0], hotmount_clamp_height], align=[-1,0,0]);
                }

                translate([(-extruder_b_w/2 * 1) + (-0.5*1), 0, hotmount_d_h[0][1]+hotmount_d_h[1][1]/2])
                {
                    hotmount_cutout(extend_cut = false);
                }
            }

        }

        // clamp mount screw holes
        for(i=[-1,1])
        {
            translate([.1, i*hotmount_clamp_screws_dist, 0])
                rotate([0,90,0])
                cylindera(d=lookup(ThreadSize, extruder_hotmount_clamp_thread), h=hotmount_clamp_thickness+.2, align=[0,0,-1], extra_h=2, round_radius=2);
        }
    }
}

extruder_a_bearing = bearing_MR105;

extruder_b_bearing = bearing_MR105;
extruder_b_w = hobbed_gear_d_outer+15*mm;

extruder_b_mount_thick = 5*mm;

extruder_b_mount_offsets=[
    /*[extruder_filapath_offset[0]-1*(extruder_b_w/2+4*mm),0,-15*mm],*/
    /*[extruder_filapath_offset[0]+1*(extruder_b_w/2+4*mm)-5*mm,0,-25*mm],*/
    /*[extruder_filapath_offset[0]-4*mm,0,44.5*mm-15*mm]*/

    [extruder_filapath_offset[0]-1*(extruder_b_w/2+4*mm),0,-15*mm],
    [extruder_filapath_offset[0]+1*(extruder_b_w/2+4*mm),0,-15*mm],
    [extruder_filapath_offset[0]-4*mm,0,44.5*mm-15*mm]
];

module extruder_b(part=undef)
{
    if(part==undef)
    {
        difference()
        {
            extruder_b(part="pos");
            extruder_b(part="neg");
        }
    }
    else if(part=="pos")
    {
        // mount onto carriage
        hull()
        {
            for(pos=extruder_b_mount_offsets)
                translate(pos)
                    cylindera(d=extruder_b_mount_dia, h=extruder_b_mount_thick, orient=[0,1,0], align=[0,1,0], round_radius=2);

            intersection()
            {
                translate(extruder_b_capmount_offset)
                translate(-[0,extruder_b_capmount_offset[1],0])
                capmount(part);
                cubea([1000,extruder_b_mount_thick,1000], align=[0,-1,0]);
            }
        }

        translate(extruder_b_capmount_offset)
        rotate([-90,0,0])
        hull()
        {
            linear_extrude(1)
                projection()
                rotate([90,0,0])
                capmount(part);

            rotate([90,0,0])
                translate(-[0,extruder_b_capmount_offset[1],0])
                capmount(part);

            rotate([90,0,0])
                capmount(part);
        }

        hull()
        /*union()*/
        {
            // main house
            extruder_b_size=[
                hobbed_gear_d_outer+5*mm,
                abs(extruder_filapath_offset[1])+hobbed_gear_h/2+extruder_b_bearing[2]+4*mm,
                hobbed_gear_d_outer+5*mm
            ];
            /*translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])*/
            /*translate([hobbed_gear_d_inner/2,0,0])*/
            /*rcubea(extruder_b_size, align=[0,sign(extruder_filapath_offset[1]),0]);*/

            // gear support
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate([0,-hobbed_gear_h/2,0])
            {
                // hobbed gear support
                cylindera(d=hobbed_gear_d_outer+5*mm, h=abs(extruder_filapath_offset[1])+hobbed_gear_h/2, align=[0,-1,0], orient=[0,1,0], round_radius=2);

                // bearing support
                cylindera(d=extruder_b_bearing[1]+5*mm, h=extruder_b_bearing[2]+3*mm, align=[0,1,0], orient=[0,1,0], round_radius=2);
            }

            // guidler screw nuts support
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate([extruder_b_guidler_screw_offset_x, 0, extruder_b_guidler_screw_offset_h])
            {
                for(i=[-1,1])
                translate([0,i*(guidler_screws_distance),  0])
                cylindera(h=house_guidler_screw_h, d=guidler_screws_mount_d, orient=[1,0,0], round_radius=2);
            }

            // guidler mount
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate(extruder_guidler_mount_off)
            {
                cylindera(d=guidler_mount_d, h=guidler_mount_w, orient=[0,1,0]);
            }

            // hotmount support
            translate(extruder_filapath_offset)
            translate([0,0,-hobbed_gear_d_outer/2 + hotmount_offset_h])
            {
                rcubea([extruder_b_w, hotmount_outer_size_xy, hotmount_outer_size_h], align=[0,0,-1]);

                translate([0,-extruder_filapath_offset[1],0])
                    rcubea([extruder_b_w, abs(extruder_filapath_offset[1]), hotmount_outer_size_h], align=[0,-1,-1]);
            }

            /* clamp mount screw holes*/
            translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
            translate([hobbed_gear_d_inner/2,0,-hobbed_gear_d_outer/2 + hotmount_offset_h])
            translate([0, 0, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
            for(x=[-1,1])
            {
                translate([x*hotmount_clamp_screws_dist, 0, 0])
                cylindera(d=lookup(ThreadSize, extruder_hotmount_clamp_thread)+6*mm, h=extruder_b_w, orient=[0,1,0]);
            }
        }

    }
    else if(part=="neg")
    {
        // mount onto carriage
        for(pos=extruder_b_mount_offsets)
        translate(pos)
        translate([0, -extruder_b_mount_thick-1*mm, 0])
        screw_cut(nut=MKnurlInsertNutM3_3_42, h=extruder_b_mount_thick, head_embed=true, nut_offset=-10, orient=[0,1,0], align=[0,1,0]);

        // guidler cutout
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        {
            guidler_w_cut = guidler_w+2*mm;
            guidler_w_cut_inner = guidler_bearing[2]+1*mm;
            guidler_w_cut_ext = 1000;
            difference()
            {
                union()
                {
                    /*hull()*/
                    {
                        /*hull()*/
                        {
                            translate([hobbed_gear_d_inner/2+3,0,0])
                            {
                                cubea([guidler_bearing[1]+1*mm,guidler_w_cut,guidler_bearing[1]*2], align=[1,0,1]);
                            }

                            // cut for guidler bearing
                            translate(extruder_guidler_mount_off)
                            translate(-[-guidler_mount_off[1],0,guidler_mount_off[2]])
                            cylindera(d=guidler_bearing[1], h=guidler_w_cut_inner, orient=[0,1,0], align=[0,0,0]);

                            // cut for guidler
                            translate(extruder_guidler_mount_off)
                            translate(-[-guidler_mount_off[1],0,guidler_mount_off[2]])
                            cylindera(d=guidler_bearing[0]*1.5+1*mm, h=guidler_w_cut, orient=[0,1,0], align=[0,0,0]);

                            // cutout pivot to make sure guidler can rotate out
                            guidler_pivot_r=pythag_hyp(abs(guidler_mount_off[1]),abs(guidler_mount_off[2]))+(guidler_bearing[1])/2;
                            translate([0,-guidler_w_cut/2,0])
                            translate(extruder_guidler_mount_off)
                            rotate([0,90,90])
                            pie_slice(guidler_pivot_r, 130, 270, guidler_w_cut);

                            translate([0,-guidler_w_cut/2,0])
                            translate(extruder_guidler_mount_off)
                            rotate([0,90,90])
                            pie_slice(guidler_pivot_r+4*mm, 125, 270, guidler_w_cut);
                        }

                        /*translate(extruder_guidler_mount_off)*/
                        /*{*/
                            /*hull()*/
                            /*for(y=[-1,1])*/
                            /*translate([0,y*guidler_mount_w/2,0])*/
                            /*{*/
                                /*cylindera(d=guidler_mount_d, h=guidler_mount_w, orient=[0,1,0], align=[0,-y,0]);*/
                                /*translate([-guidler_mount_d,0,-guidler_mount_d/2])*/
                                    /*cubea([10,(guidler_w-guidler_mount_w)/2+1*mm,10], align=[1,y,1]);*/
                            /*}*/
                        /*}*/
                    }
                    translate(extruder_guidler_mount_off)
                    {
                        cylindera(d=guidler_mount_d+3*mm, h=guidler_w_cut, orient=[0,1,0], align=[0,0,0]);

                        translate(-[0,extruder_filapath_offset[1],0])
                        translate(-[0,extruder_b_mount_thickness/2,0])
                        hull()
                        {
                            cylindera(d=guidler_screws_thread_dia+2*mm, h=guidler_w_cut_ext, orient=[0,1,0], align=[0,1,0]);
                            translate([0,0,-(guidler_screws_thread_dia+0*mm)])
                            cubea([10,guidler_w_cut_ext,100], align=[1,-1,1]);
                        }
                    }
                }
                // dont cut away the guilder mount
                translate(extruder_guidler_mount_off)
                {
                    cylindera(d=guidler_mount_d, h=guidler_mount_w, orient=[0,1,0]);
                    cubea([guidler_mount_d, guidler_mount_w, 10], align=[0,0,-1]);
                }
            }
        }

        // guidler screws cutouts
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        for(y=[-1,1])
        translate([extruder_b_guidler_screw_offset_x, y*(guidler_screws_distance), extruder_b_guidler_screw_offset_h])
        {
            r= guidler_screws_thread_dia/2 * 1.1;
            cubea([1000, r*2, r]);

            for(v=[-1,1])
                translate([0,0, v*r/2])
                    cylindera(r=r,h=1000, orient=[1,0,0]);

            // guidler screw nuts drop-in slots
            translate([0,0, -r*2])
                cubea([nut_m3[2]*1.25,nut_m3[1]+.5*mm,house_guidler_screw_h], align=[0,0,1], extrasize=[0,0,1], extrasize_align=[0,0,1]);
        }

        // guidler mount screw
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate(extruder_guidler_mount_off)
        {
            cylindera(d=lookup(ThreadSize, guidler_screws_thread), h=guidler_mount_w+.1, orient=[0,1,0]);
        }

        // cutout for hobbed gear (inner)
        cylindera(
                h=abs(extruder_filapath_offset[1])+hobbed_gear_h/2+1.1*mm,
                d=hobbed_gear_d_outer+1.5*mm,
                orient=[0,1,0],
                align=[0,1,0]
                );

        // hotmount clamp screws
        translate([hobbed_gear_d_inner/2, 0,-hobbed_gear_d_outer/2 + hotmount_offset_h])
        for(i=[-1,1])
        {
            translate([i*hotmount_clamp_screws_dist, 0, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
                screw_cut(nut=MKnurlInsertNutM3_5_42, h=1000, nut_offset=5*mm, head_embed=false, orient=[0,1,0], align=[0,-1,0]);
        }

        // filament path
        translate(extruder_filapath_offset)
        {
            // above drive gear
            cylindera(h=1000, d=filament_d+.7*mm, orient=[0,0,1], align=[0,0,1]);

            // below drive gear (into hotend)
            cylindera(h=1000, d=4*mm, orient=[0,0,1], align=[0,0,-1]);
        }

        // gear cutout
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate([0,-hobbed_gear_h/2-.5*mm,0])
        cylindera(d=extruder_b_bearing[1]+.3*mm, h=extruder_b_bearing[2]+.5*mm, align=[0,1,0], orient=[0,1,0]);

        // gear cutout
        cylindera(h=abs(extruder_filapath_offset[1])+hobbed_gear_h/2+extruder_b_bearing[2]+1*mm, d=extruder_b_bearing[1]+.1*mm, orient=[0,1,0], align=[0,1,0]);

        // extruder shaft
        /*extruder_shaft_len = 1000;*/
        extruder_shaft_len = abs(extruder_filapath_offset[1])+hobbed_gear_h/2+extruder_b_bearing[2]+1*mm;
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate([0,-extruder_filapath_offset[1]+.1,0])
        cylindera(h=extruder_shaft_len, d=extruder_shaft_d, orient=[0,1,0], align=[0,1,0]);

        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        translate([hobbed_gear_d_inner/2,0,-hobbed_gear_d_outer/2 + hotmount_offset_h+.01])
        rotate([0,0,-90])
        {
            hotmount_cutout(extend_cut=true);

            // clamp mount screw holes
            for(i=[-1,1])
            {
                translate([0, i*hotmount_clamp_screws_dist, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
                    cylindera(d=lookup(ThreadSize, extruder_hotmount_clamp_thread), h=extruder_b_w+1, orient=[1,0,0]);
            }

            // hotmount clamp cutout
            translate([extruder_b_w/2, 0, -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
            {
                rcubea([hotmount_clamp_thickness+1.2, hotmount_clamp_y+0.2, hotmount_clamp_height+0.2], align=[-1,0,0], extrasize=[100,0,0], extrasize_align=[1,0,0]);
            }
        }

        translate(extruder_b_capmount_offset)
            capmount(part);
    }
    else if(part=="vit")
    {
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        {
            translate([hobbed_gear_d_inner/2,0,-hobbed_gear_d_outer/2 + hotmount_offset_h+.01])
            translate([0, -extruder_b_w/2 * (1), -hotmount_d_h[0][1]-hotmount_d_h[1][1]/2])
            rotate([0,0,-90])
            hotmount_clamp();

            translate([0,-hobbed_gear_h/2-extruder_b_bearing[2]-.5*mm,0])
            {
                cylindera(h=extruder_a_h+extruder_offset_a[1]-extruder_filapath_offset[1], d=extruder_shaft_d, orient=[0,1,0], align=[0,-1,0]);

                bearing(extruder_b_bearing, orient=[0,1,0], align=[0,1,0]);
            }

            // hobbed gear
            cylindera(h=hobbed_gear_h, d=hobbed_gear_d_inner, orient=[0,1,0], align=[0,0,0]);
            for(y=[-1,1])
            translate([0,y*hobbed_gear_h/2,0])
            {
                cylindera(h=hobbed_gear_h/3, d=hobbed_gear_d_outer, orient=[0,1,0], align=[0,y,0]);
            }
        }
        translate(extruder_b_capmount_offset)
            capmount(part);
    }
}

// Final part
module x_carriage_withmounts(show_vitamins=false)
{
    difference()
    {
        /*hull()*/
        union()
        {
            x_carriage(mode="pos");

            // extruder A mount
            translate(extruder_offset)
            translate(extruder_offset_a)
            {
                for(x=[-1,1])
                for(z=[-1,1])
                {
                    if(x!=-1||z!=-1)
                    translate([x*extruder_motor_holedist/2,0,z*extruder_motor_holedist/2])
                        cylindera(d=extruder_b_mount_thickness, h=extruder_offset_a[1], orient=[0,1,0], align=[0,1,0], round_radius=2);
                }
            }
        }

        x_carriage(mode="neg");

        // rod between extruder part A and B
        translate(extruder_offset)
        {
            cylindera(h=100*mm, d=extruder_shaft_d+2*mm, orient=[0,1,0], align=[0,0,0]);
        }

        // extruder A mount cutout
        translate(extruder_offset)
        translate(extruder_offset_a)
        translate(-[0,extruder_offset_a[1],0])
        {
            for(x=[-1,1])
            for(z=[-1,1])
            translate([x*extruder_motor_holedist/2,0,z*extruder_motor_holedist/2])
            translate([0,.1,0])
            screw_cut(
                    nut=MHexNutM3,
                    h=extruder_offset_a[1]+.2,
                    head_embed=true,
                    with_nut=false,
                    orient=[0,1,0],
                    align=[0,1,0]
                    );
        }

        // extruder B mount cutout
        translate(extruder_offset)
        {
            for(pos=extruder_b_mount_offsets)
            translate(pos)
            screw_cut(nut=MKnurlInsertNutM3_3_42, h=5, head_embed=false, orient=[0,1,0], align=[0,1,0]);
        }
    }

    if(show_vitamins)
    {
        x_carriage(mode="vit");
    }
}

module x_extruder_hotend()
{
    hotend_conn =[[0,0,27.8-hotmount_offset_h],[0,0,1]];
    translate(extruder_filapath_offset)
    attach([[0,0,0]], hotend_conn)
        rotate([90,0,270])
        %import("stl/E3D_V6_1.75mm_Universal_HotEnd_Mockup.stl");

}

guidler_bearing = bearing_MR105;

guidler_mount_off = [0,-guidler_bearing[1]/1.8, -guidler_bearing[1]/1.4];
extruder_guidler_mount_off = [-.3*mm -guidler_mount_off[1]+hobbed_gear_d_outer/2+guidler_bearing[1]/2,0,guidler_mount_off[2]];

// length of the guidler bearing bolt/screw
guidler_mount_w=guidler_bearing[2];
guidler_mount_d=8*mm;
guidler_bolt_h=guidler_bearing[2]+4*mm;

guidler_w=max(guidler_mount_w+9*mm, guidler_bearing[2]*2.8);
guidler_d=5;
guidler_h=7;
guidler_extra_h_up=guidler_bearing[1]/2+hotmount_clamp_screw_dia/2;

guidler_screws_thread = ThreadM3;
guidler_screws_thread_dia= lookup(ThreadSize, guidler_screws_thread);
guidler_screws_distance=4*mm;
guidler_screws_mount_d = guidler_screws_thread_dia*2+5*mm;

guidler_srew_distance = 10;

house_guidler_screw_h = guidler_screws_thread_dia+10*mm;

extruder_b_guidler_screw_offset_h = 15*mm + guidler_screws_thread_dia -6*mm;
extruder_b_guidler_screw_offset_x = 2*mm;

extruder_b_mount_thickness = 10*mm;
extruder_b_mount_dia = 11*mm;

module extruder_guidler()
{
    // everything inside this module is relative to the center of the
    // bearing (that clamps the filament)
    difference()
    {
        union()
        {

            hull()
            {
                // guidler main block
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, 0])
                rcubea([guidler_w, guidler_d, guidler_h], align=[0,1,0]);

                // guidler bearing bolt holder
                cylindera(d=guidler_bearing[0]*1.5,h=guidler_w, orient=[1,0,0], round_radius=2);
            }

            hull()
            {
                // guidler main block
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, 0])
                rcubea([guidler_w, guidler_d, guidler_h], align=[0,1,0], extrasize=[0,0,guidler_extra_h_up], extrasize_align=[0,0,1]);

                // guidler mount point
                translate([0,guidler_mount_off[1], guidler_mount_off[2]])
                cylindera(d=guidler_mount_d,h=guidler_w, orient=[1,0,0], round_radius=2);
            }

            hull()
            {
                // guidler main block
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, guidler_h])
                rcubea([guidler_w, guidler_d, 1], align=[0,1,0]);

                // guidler screws mount
                for(i=[-1,1])
                translate([i*(guidler_screws_distance),guidler_mount_off[1]-guidler_mount_d/2, extruder_b_guidler_screw_offset_h])
                cylindera(r=guidler_screws_thread_dia/2*3,h=guidler_d, align=[0,-1,0], orient=[0,1,0], round_radius=2);

                // tab above screw mount, for easier open
                translate([0,guidler_mount_off[1]-guidler_mount_d/2, extruder_b_guidler_screw_offset_h+guidler_screws_thread_dia/2*3])
                cylindera(r=5*mm,h=guidler_d/2, align=[0,-1,0], orient=[0,1,0], round_radius=2);

            }
        }

        // cutouts for clamping screws
        for(i=[-1,1])
        translate([i*(guidler_screws_distance),guidler_mount_off[1]-guidler_mount_d/2, extruder_b_guidler_screw_offset_h])
        {
            r= guidler_screws_thread_dia/2*1.1;
            translate([0, -0.1, 0])
            {
                cubea([r*2,guidler_d+.2,r], align=[0,1,0]);
                for(v=[-1,1])
                translate([0, 0, v*r/2])
                {
                    cylindera(r=r,h=guidler_d+.2, align=[0,-1,0], orient=[0,1,0]);
                }
            }

        }

        // port hole to see bearing
        translate([0,-guidler_bearing[1]/2,0])
        cubea([guidler_bearing[0]*1.1, 100, guidler_bearing[1]/2], align=[0,0,1]);

        // cutout middle mount point pivot
        translate([0,guidler_mount_off[1], guidler_mount_off[2]])
        cylindera(d=guidler_mount_d+2*mm,h=guidler_mount_w+1*mm, orient=[1,0,0]);

        // mount bolt hole
        translate([0,guidler_mount_off[1], guidler_mount_off[2]])
        cylindera(d=lookup(ThreadSize, guidler_screws_thread),h=100, orient=[1,0,0]);

        // guidler bearing bolt holder cutout
        union()
        {
            cubea([guidler_bolt_h*1.05+2*e,guidler_bearing[0]*1.05,guidler_bearing[0]*1.05],align=[0,1,0]);

            cylindera(d=guidler_bearing[0]*1.05, h=guidler_bolt_h*1.05, orient=[1,0,0]);
        }

        // guidler bearing cutout
        cylindera(d=guidler_bearing[1]*1.1, h=guidler_bearing[2]*1.1, orient=[1,0,0]);

    }

    if(show_extras)
    {
        cylindera(d=guidler_bearing[1], h=guidler_bearing[2], orient=[1,0,0]);
        cylindera(d=guidler_bearing[0], h=guidler_bolt_h, orient=[1,0,0]);
    }
}

module capmount(part=undef, height=10,thickness=5,screws_spacing=21,screw_offset=[1,0],screws_diameter=4,sensor_spacing=3,sensor_height=[15,40,5],sensor_diameter=12)
{
    align=[0,-1,0];

    OD_cut = 0*mm;
    OD = sensor_diameter+2*thickness;
    h_ = height;
    sensor_h = v_sum(sensor_height,2);

    size_align(size=[OD,OD-2*OD_cut,h_], align=align, orient=[0,0,1])
    {

        if(part == "pos")
        {
            //Sensor mount
            cylindera(d=OD, h=h_);
            cubea([OD,OD/2,h_], align=[0,1,0]);
        }

        else if(part == "neg")
        {
            translate([0,0,h_/2])
            cylindera(d=OD+1*mm, h=sensor_h, align=[0,0,1]);

            cylindera(d=sensor_diameter+0,5, h=h_+.2);

            translate([0,0,-h_/2])
            cylindera(d=OD+1*mm, h=sensor_h, align=[0,0,-1]);

            for(y=[-1,1])
                translate([0,y*OD/2, 0])
                    cubea([sensor_diameter+thickness*2,OD_cut,h_+2*e],[0,-y,0]);
        }
        else if(part == "vit")
        {
            translate([0,0,sensor_h/2])
            {
                for(e=v_itrlen(sensor_height))
                {
                    hs=v_sum(sensor_height,e-1);
                    translate([0,0,-hs])
                        if(e==0||e==2)
                            color([0.3,.4,0])
                                cylindera(d=sensor_diameter,h=sensor_height[e], align=[0,0,-1]);
                        else
                            cylindera(d=sensor_diameter,h=sensor_height[e], align=[0,0,-1]);
                }
            }
        }
    }
}

module e3d_heatsink_duct()
{
    hotend_heatsink_diameter = 25;
    hotend_heatsink_height = 32;
    hotend_heatsink_offset = 16; // offset off bottom of body that heatsink starts

    length = 55;
    width = 40;
    height = hotend_heatsink_offset+hotend_heatsink_height;

    fan_hole_dist = 32;
    m3_hexnut_dia = 6.4;
    m3_hexnut_flat_dia = 5.54;
    m3_hexnut_thickness = 2.4;

    difference() {
        union() {
            //cube([length, width, hotend_heatsink_offset+hotend_heatsink_height]);
            hull() {
                translate([0,0,20]) cube([20,40,height-20]);
                translate([50,5+17.5,height/2+20/2]) cube([5,30,height-20],center=true);
                translate([1,20,20]) rotate([0, 90, 0]) cylinder(r=38/2,h=1,center=true);
            }
        }

        // hotend heatsink hole
        translate([50, 5+17.75, hotend_heatsink_offset]) cylinder(r=hotend_heatsink_diameter/2, hotend_heatsink_height+1);
        translate([50, 5+17.75, 0]) cylinder(r=25/2, hotend_heatsink_offset+1);

        // first portion of fan duct
        difference() {
            hull() {
                translate([-1,20,20]) rotate([0, 90, 0]) cylinder(r=35/2,h=1,center=true);
                translate([50,5+17.5,24+25/2]) cube([20,20,20],center=true);
            }
            /*// support material ribs*/
            /*translate([0,12,0]) cube([length, 1, height]);*/
            /*translate([0,18,0]) cube([length, 1, height]);*/
            /*translate([0,23,0]) cube([length, 1, height]);*/
            /*translate([0,28,0]) cube([length, 1, height]);*/
        }

        // m3 traps for fan
        for (end = [-1,1]) {
            translate([-1,20+end*fan_hole_dist/2,20+fan_hole_dist/2]) rotate([0,90,0]) cylinder(r=1.6,h=30,center=true, $fn=7);
            translate([5,20+end*fan_hole_dist/2,20+fan_hole_dist/2]) rotate([0,90,0]) rotate([0,0,30]) cylinder(r=m3_hexnut_dia/2,h=m3_hexnut_thickness,center=true,$fn=6);
            translate([5-m3_hexnut_thickness/2,20+end*fan_hole_dist/2,20+fan_hole_dist/2]) rotate([end*-90,0,0]) translate([0,-m3_hexnut_flat_dia/2,0]) cube([m3_hexnut_thickness,m3_hexnut_flat_dia,10]);
        }

        if (1) {
            // clearance existing fan mounts
            cube([10,width,8]);

            // hole for clearance for wingnuts
            //translate([10,0,0]) cube([length-10,width+1,10]);

            translate([25, 5+17.75, 9]) cylinder(r=2.5, h=5, center=true);

        }
        else
        {
            // whatever. just get rid of everything for the bottom whatever mm
            //translate([-1,-1,-1]) cube([length+2,width+2,18+1]);
        }

        // clearance for bearing holder
        translate([18,0,0]) cube([40,5,25]);
        translate([10-3,0,0]) cube([50,9,6.5]);

        // TODO; clearance for extruder mounting bolt
    }
}

// flip for printing
/*e3d_heatsink_duct();*/

// extruder guidler mount point
extruder_conn_guidler = [ extruder_guidler_mount_off, [0,1,0]];

// guidler connection point
extruder_guidler_conn_mount = [ guidler_mount_off,  [1,0,0]];
extruder_guidler_roll = 45;

    if(false)
attach(extruder_conn_guidler, extruder_guidler_conn_mount, extruder_guidler_roll)
{
    extruder_guidler(show_extras=true);
}

if(false)
extruder_a(show_vitamins=true);

alpha = 0.7;
/*alpha = 1;*/
color_xcarriage = [0.3,0.5,0.3, alpha];
color_hotend = [0.8,0.4,0.4, alpha];
color_extruder = [0.2,0.6,0.9, alpha];
color_guidler = [0.4,0.5,0.8, alpha];
color_filament = [0,0,0, alpha];

extruder_b_capmount_offset=[35,-7,-41];

module x_carriage_full()
{
    color(color_xcarriage)
    x_carriage_withmounts(show_vitamins=true);

    translate(extruder_offset)
    {
        color(color_extruder)
        translate(extruder_offset_a)
        extruder_a(show_vitamins=true);

        color(color_extruder)
        {
            difference()
            {
                extruder_b(part="pos");

                extruder_b(part="neg");
            }
        }
        extruder_b(part="vit");

        color(color_guidler)
        translate(extruder_filapath_offset-[hobbed_gear_d_inner/2,0,0])
        attach(extruder_conn_guidler, extruder_guidler_conn_mount, extruder_guidler_roll)
        {
            extruder_guidler(show_extras=true);
        }

        translate([-95,53,20])
        rotate([-152,0,0])
        import("stl/E3D_40_mm_Duct.stl");

        translate([-123.5,78.5,-54])
        rotate([0,0,-90])
        import("stl/E3D_30_mm_Duct.stl");

        color(color_hotend)
        x_extruder_hotend();

        //filament path
        color(color_filament)
        translate(extruder_filapath_offset)
        cylindera(h=1000, d=1.75*mm, orient=[0,0,1], align=[0,0,0]);
    }
}

if(false)
{
    /*rotate([90,0,0])*/
    /*x_carriage_withmounts(show_vitamins=false);*/

    /*rotate([-90,0,0])*/
    /*extruder_a();*/

    /*rotate([-90,0,0])*/
    /*extruder_b();*/

    guidler_conn_layflat = [ [0, guidler_mount_off[1]-guidler_mount_d/2, guidler_mount_off[2]],  [0,-1,0]];
    attach([[0*mm,0*mm,0],[0,0,-1]], guidler_conn_layflat)
    {
        extruder_guidler(show_extras=false);
    }

    /*hotmount_clamp();*/
}


More tweaks

More tweaks

//
// This is the iotsa board itself, including the important connectors and
// holes. You can define here if you have shortened the board, which will
// not only change the board itself, but also the box we are going to create around it.
//
iotsaBoardXSize = 63.5;   // one dimension of the unmodified board
iotsaBoardYSize = 43.5;   // the other dimension of the board
numberOfRowsRemoved = 0;
extraMMRemoved = 0; // 0 if nothing removed, 2.2 if any rows removed.
numberOfMMRemoved = extraMMRemoved + (numberOfRowsRemoved*2.54);

boardThickness = 1.8; // The thickness of the PCB board
regulatorAngle = 35; // 0, or higher if you've bent the regulator over backwards.

esp12AntennaStickout = 5; // How many mm the esp12 antenna sticks out of the iotsa board

module iotsaBoard() {
    module esp12() {
        union() {
            cube([24, 16, 2]); // the esp-12 board
            translate([8, 1.5, 2]) cube([15, 13, 2.5]); // the metal cap
        }
    }
    module regulator() {
        rotate([-regulatorAngle, 0, 0])
        translate([0, 0, 5])
        union() {
            translate([0, 4.5, 0]) cube([10.2, 1.3, 15]);
            translate([0, 0, 0]) cube([10.2, 4.5, 8.5]);
        }
    }
    module powerjack() {
        difference() {
            cube([9, 15, 11]);
            translate([4.5, -1, 7]) rotate([-90, 0, 0]) cylinder(14, d=6);
        }
    }
    translate([0, 0, -1.8])
    union() {
        // The board
        difference() {
            cube([iotsaBoardXSize-numberOfMMRemoved,iotsaBoardYSize,1.8]);
            translate([2, 2, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([2, 41, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([36.5, 2, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([36.5, 41, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([60.5, 2, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([60.5, 41, -0.1]) cylinder(2, d=2, center=false, $fn=12);
        }
        // The components
        translate([-esp12AntennaStickout, 13.5, 1.8]) esp12();
        translate([20, 15, 1.8]) regulator();
        translate([22, -3, 1.8]) powerjack();
    }
}

//
// Box parameters. We are going to compute the size from the parameters.
//
iotsaComponentHeight = 14;  // Make sure this is high enough
iotsaSolderingHeight = 3;   // How far the soldering extends below the board.
boxThickness = 1.5;
boxBottomThickness = boxThickness;
boxFrontThickness = boxThickness;   // This is where the power connector is
boxLeftThickness = boxThickness;
boxRightThickness = boxThickness;
boxBackThickness = boxThickness;
boxTopThickness = boxThickness;

leeWay = 0.3;   // gap we want between board and box (on all sides, individually)

module box() {
    innerXSize = (iotsaBoardXSize-numberOfMMRemoved) + esp12AntennaStickout + 2*leeWay;
    innerYSize = iotsaBoardYSize + 2*leeWay;
    innerZSize = boardThickness + iotsaComponentHeight + iotsaSolderingHeight + 2*leeWay;

    outerXSize = innerXSize + boxLeftThickness + boxRightThickness;
    outerYSize = innerYSize + boxFrontThickness + boxBackThickness;
    outerZSize = innerZSize + boxBottomThickness + boxTopThickness;

    strutThickness = 2;
    retainerWidth = 3;
    retainerLength = 6;

    module basicBox() {
         difference() {
            cube([outerXSize, outerYSize, outerZSize-boxTopThickness]);
            translate([boxLeftThickness, boxFrontThickness, boxBottomThickness])
                cube([innerXSize, innerYSize, innerZSize+1]);
        }
    }
    module frontHoles() {
        // Holes in the front. X and Z relative to iotsa frontleft corner, Y should be 2*frontThickness.
        translate([22-leeWay, 0, 0-leeWay]) cube([9+2*leeWay, 2*boxFrontThickness, 11+2*leeWay]);
    }
    module rightHoles() {
    }
    module bottomHoles() {
        // Holes in the bottom. X and Y are relative to inner box frontleft corner, Z should be 2*bottomThickness
        translate([3, 3+strutThickness, 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
        translate([innerXSize-3, 3+strutThickness, 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
        translate([3, innerYSize-(3+strutThickness), 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
        translate([innerXSize-3, innerYSize-(3+strutThickness), 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
        translate([innerXSize/2, innerYSize/2, 0]) cylinder(2*boxBottomThickness, d=6, $fn=12);
    }

    union() {
        difference() {
            translate([-esp12AntennaStickout-boxLeftThickness-leeWay, -boxFrontThickness-leeWay, -(boardThickness+iotsaSolderingHeight+boxBottomThickness+leeWay)])
                union() {
                    // The box itself, with the cutouts for the lid
                    difference() {
                        basicBox();
                        // Front cutout
                        translate([boxLeftThickness, -0.5*boxFrontThickness, outerZSize-boxTopThickness-boxBottomThickness])
                            cube([innerXSize, 2*boxFrontThickness, 2*boxTopThickness]);
                        // back cutout
                        * translate([boxLeftThickness, innerYSize+boxFrontThickness-0.5*leeWay, outerZSize-boxTopThickness-boxBottomThickness])
                            cube([innerXSize, 0.5*boxBackThickness+leeWay, 0.5*boxTopThickness]);

                        // front left retainer hole
                        translate([boxLeftThickness,-0.5*boxFrontThickness, outerZSize-boxTopThickness-boxBottomThickness-retainerLength])
                            cube([retainerWidth, 2*boxFrontThickness, retainerWidth]);
                        // front right retainer hole
                        translate([outerXSize-boxRightThickness-retainerWidth, -0.5*boxFrontThickness, outerZSize-boxTopThickness-boxBottomThickness-retainerLength])
                            cube([retainerWidth, 2*boxFrontThickness, retainerWidth]);

                        // back left retainer hole
                        translate([boxLeftThickness,innerYSize+boxFrontThickness-0.5*boxBackThickness, outerZSize-boxTopThickness-boxBottomThickness-retainerLength])
                            cube([retainerWidth, 2*boxBackThickness, retainerWidth]);
                        // back right retainer hole
                        translate([outerXSize-boxRightThickness-retainerWidth, innerYSize+boxFrontThickness-0.5*boxBackThickness, outerZSize-boxTopThickness-boxBottomThickness-retainerLength])
                            cube([retainerWidth, 2*boxBackThickness, retainerWidth]);
                    }
                    // The front support for the iotsa board
                    cube([outerXSize, boxFrontThickness+strutThickness, boxBottomThickness+iotsaSolderingHeight]);
                    // The back support for the outsa board
                    translate([0, innerYSize+boxFrontThickness-strutThickness, 0])
                        cube([outerXSize, boxBackThickness+strutThickness, boxBottomThickness+iotsaSolderingHeight]);
                }
                translate([0, -1.5*boxFrontThickness-leeWay, 0]) frontHoles();
                * translate() rightHoles();
                translate([-esp12AntennaStickout, -leeWay, -(boardThickness+iotsaSolderingHeight+1.5*boxBottomThickness+leeWay)]) bottomHoles();
            }
        % iotsaBoard();
    }
}
box();

//
// This is the iotsa board itself, including the important connectors and
// holes. You can define here if you have shortened the board, which will
// not only change the board itself, but also the box we are going to create around it.
//
numberOfRowsRemoved = 0;
extraMMRemoved = 0; // 0 if nothing removed, 2.2 if any rows removed.
numberOfMMRemoved = extraMMRemoved + (numberOfRowsRemoved*2.54);

boardThickness = 1.8; // The thickness of the PCB board
regulatorAngle = 35; // 0, or higher if you've bent the regulator over backwards.

esp12AntennaStickout = 5; // How many mm the esp12 antenna sticks out of the iotsa board

module iotsaBoard() {
    module esp12() {
        union() {
            cube([24, 16, 2]); // the esp-12 board
            translate([8, 1.5, 2]) cube([15, 13, 2.5]); // the metal cap
        }
    }
    module regulator() {
        rotate([-regulatorAngle, 0, 0])
        translate([0, 0, 5])
        union() {
            translate([0, 4.5, 0]) cube([10.2, 1.3, 15]);
            translate([0, 0, 0]) cube([10.2, 4.5, 8.5]);
        }
    }
    module powerjack() {
        difference() {
            cube([9, 15, 11]);
            translate([4.5, -1, 7]) rotate([-90, 0, 0]) cylinder(14, d=6);
        }
    }
    translate([0, 0, -1.8])
    union() {
        // The board
        difference() {
            cube([63-numberOfMMRemoved,43,1.8]);
            translate([2, 2, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([2, 41, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([36.5, 2, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([36.5, 41, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([60.5, 2, -0.1]) cylinder(2, d=2, center=false, $fn=12);
            translate([60.5, 41, -0.1]) cylinder(2, d=2, center=false, $fn=12);
        }
        // The components
        translate([-esp12AntennaStickout, 13.5, 1.8]) esp12();
        translate([20, 15, 1.8]) regulator();
        translate([22, -3, 1.8]) powerjack();
    }
}

//
// Box parameters. We are going to compute the size from the parameters.
//
iotsaComponentHeight = 14;  // Make sure this is high enough
iotsaSolderingHeight = 3;   // How far the soldering extends below the board.
boxThickness = 1.5;
boxBottomThickness = boxThickness;
boxFrontThickness = boxThickness;   // This is where the power connector is
boxLeftThickness = boxThickness;
boxRightThickness = boxThickness;
boxBackThickness = boxThickness;
boxTopThickness = boxThickness;

leeWay = 0.3;   // gap we want between board and box (on all sides, individually)

module box() {
    innerXSize = (63-numberOfMMRemoved) + esp12AntennaStickout + 2*leeWay;
    innerYSize = 43 + 2*leeWay;
    innerZSize = boardThickness + iotsaComponentHeight + iotsaSolderingHeight + 2*leeWay;

    outerXSize = innerXSize + boxLeftThickness + boxRightThickness;
    outerYSize = innerYSize + boxFrontThickness + boxBackThickness;
    outerZSize = innerZSize + boxBottomThickness + boxTopThickness;

    strutThickness = 2;
    retainerWidth = 3;
    retainerLength = 6;

    module basicBox() {
         difference() {
            cube([outerXSize, outerYSize, outerZSize-boxTopThickness]);
            translate([boxLeftThickness, boxFrontThickness, boxBottomThickness])
                cube([innerXSize, innerYSize, innerZSize+1]);
        }
    }
    module frontHoles() {
        // Holes in the front. X and Z relative to iotsa frontleft corner, Y should be 2*frontThickness.
        translate([22-leeWay, 0, 0-leeWay]) cube([9+2*leeWay, 2*boxFrontThickness, 11+2*leeWay]);
    }
    module rightHoles() {
    }
    module bottomHoles() {
        // Holes in the bottom. X and Y are relative to inner box frontleft corner, Z should be 2*bottomThickness
        translate([3, 3+strutThickness, 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
        translate([innerXSize-3, 3+strutThickness, 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
        translate([3, innerYSize-(3+strutThickness), 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
        translate([innerXSize-3, innerYSize-(3+strutThickness), 0]) cylinder(2*boxBottomThickness, d=3, $fn=12);
    }

    union() {
        difference() {
            translate([-esp12AntennaStickout-boxLeftThickness-leeWay, -boxFrontThickness-leeWay, -(boardThickness+iotsaSolderingHeight+boxBottomThickness+leeWay)])
                union() {
                    // The box itself, with the cutouts for the lid
                    difference() {
                        basicBox();
                        // Front cutout
                        translate([boxLeftThickness, -0.5*boxFrontThickness, outerZSize-boxTopThickness-boxBottomThickness])
                            cube([innerXSize, 2*boxFrontThickness, 2*boxTopThickness]);
                        // back cutout
                        translate([boxLeftThickness, innerYSize+boxFrontThickness-0.5*leeWay, outerZSize-boxTopThickness-boxBottomThickness])
                            cube([innerXSize, 0.5*boxBackThickness+leeWay, 0.5*boxTopThickness]);
                        // left retainer hole
                        translate([boxLeftThickness,-0.5*boxFrontThickness, outerZSize-boxTopThickness-boxBottomThickness-retainerLength])
                            cube([retainerWidth, 2*boxFrontThickness, retainerWidth]);
                        // right retainer hole
                        translate([outerXSize-boxRightThickness-retainerWidth, -0.5*boxFrontThickness, outerZSize-boxTopThickness-boxBottomThickness-retainerLength])
                            cube([retainerWidth, 2*boxFrontThickness, retainerWidth]);
                    }
                    // The front support for the iotsa board
                    cube([outerXSize, boxFrontThickness+strutThickness, boxBottomThickness+iotsaSolderingHeight]);
                    // The back support for the outsa board
                    translate([0, innerYSize+boxFrontThickness-strutThickness, 0])
                        cube([outerXSize, boxBackThickness+strutThickness, boxBottomThickness+iotsaSolderingHeight]);
                }
                translate([0, -1.5*boxFrontThickness-leeWay, 0]) frontHoles();
                * translate() rightHoles();
                translate([-esp12AntennaStickout, -leeWay, -(boardThickness+iotsaSolderingHeight+1.5*boxBottomThickness+leeWay)]) bottomHoles();
            }
        % iotsaBoard();
    }
}
box();


hole's wall is now thicker

hole's wall is now thicker

module joint(groundSpacing)
{
  hch = groundSpacing + 8/2;  // hole center height

  difference()
  {
    // main element
    union()
    {
      cube([3, 8, hch]);
      translate([0, 8/2, hch])
        rotate([0, 90, 0])
          cylinder(r=8/2, h=3, $fs=0.01);
    }
    // screw hole
    translate([-1, 8/2, hch])
      rotate([0, 90, 0])
        cylinder(r=4.5/2, h=3+2*1, $fs=0.01);
  }
}

joint(1);

module joint(groundSpacing)
{
  hch = groundSpacing + 6.5/2;  // hole center height

  difference()
  {
    // main element
    union()
    {
      cube([3, 6.5, hch]);
      translate([0, 6.5/2, hch])
        rotate([0, 90, 0])
          cylinder(r=6.5/2, h=3, $fs=0.01);
    }
    // screw hole
    translate([-1, 6.5/2, hch])
      rotate([0, 90, 0])
        cylinder(r=4.5/2, h=3+2*1, $fs=0.01);
  }
}

joint(1);