// challenge-bot
// GNU AGPLv3 (or later at your option)
// project available at these locations:
// https://gitorious.org/ozzloy/challenge-bot
// https://github.com/waynegramlich/challenge-bot

$fn = 100;

module ball_screws(){
  between = 14.732;  // 0.580 inches
  screw_radius = 2.286/2;  // 0.090 inches
  screw_length = 8;  // i eyeballed this
  translate([between/2, 0, 0]) cylinder(h = screw_length, r = screw_radius);
  translate([-between/2, 0, 0]) cylinder(h = screw_length, r = screw_radius);}

module caster_flange(){
  // i eyeballed this too, it's (0.580/5) inches, times 2 to be stronger
  height = 2.9464 * 2;
  width = 20.32;  // 0.800 inches
  between = 14.732;  //0.580 inches
  side_radius = (width - between)/2;
  hull(){
    cylinder(h = height, r = between/2);
    translate([between/2, 0, 0]) cylinder(h = height, r = side_radius);
    translate([-between/2, 0, 0]) cylinder(h = height, r = side_radius);}}

module hexagon(size, height){
    boxWidth = size/1.75;
    for (r = [-60, 0, 60]) rotate([0,0,r]) cube([boxWidth, size, height], true);}

module nuts(){
  height = 1.6;  // from calipers
  overall_width = 20.32;  // 0.800 inches
  between = 14.732;  // 0.580 inches
  short_side_nut = 4.7;  // from calipers
  translate([between/2, 0, height/2]) hexagon(4.7, height);
  translate([-between/2, 0, height/2]) hexagon(4.7, height);}

module ziptie(){
  ziptie_width = 4.7625; // 3/16 inch
  ziptie_height = 3; // i'm guessing
  standoff_radius = 14.732; // 0.580 inches
  translate([-standoff_radius/2, -ziptie_width/2, 0])
    cube([standoff_radius, ziptie_width, ziptie_height]);}

module caster_standoff(){
  height = 43;
  caster_radius = 14.732/2;
  caster_flange_height = 2.9464 * 2;
  difference(){
    union(){
      cylinder(h = height, r = caster_radius);
      caster_flange();}
    translate([0, 0, -.1]) scale([1, 1, 1.1]) ball_screws();
    translate([0, 0, caster_flange_height]) nuts();
    translate([0, 0, height * 3 / 4]) scale([1.1, 1, 1]) ziptie();
    rotate([0, 0, 90]) translate([0, 0, height * 1 / 2]) scale([1.1, 1, 1])
      ziptie();}}

caster_standoff();