// 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

// use this drill jig for putting holes in a motor mount for screws
//  and motor shaft.  the four tabs at the bottom are for clamping
//  the jig down.

mm_per_inch = 25.4;

material_width = (1 / 8) * mm_per_inch;

board_length = 1.75 * mm_per_inch;
board_width = 1.5 * mm_per_inch;
board_depth = (3 / 16) * mm_per_inch;
tab_length = 3 * mm_per_inch;
tab_width = (1 / 4) * mm_per_inch;

union(){
  rotate(a = 90, v = [1, 0, 0]) {
    cube([board_length + material_width,
          1.75 * mm_per_inch + material_width,
          material_width]);}

  translate(v = [0, -material_width, 0]){
    rotate(a = -90, v = [0, 1, 0]) {
      cube( [1.75 * mm_per_inch + material_width,
             1.5 * mm_per_inch + 2 * material_width,
             material_width]);}}

  translate(v = [(1.75 * mm_per_inch + material_width) / 2 + tab_width,
                 -tab_length,
                 0]){
    rotate(a = 90, v = [0 ,0 ,1 ]){
      cube([3 * mm_per_inch, 0.5 * mm_per_inch , material_width]);}}

  translate(v = [-tab_length,
                 (1.5 * mm_per_inch + material_width) / 2 - tab_width,
                 0]){
    cube([3 * mm_per_inch, 0.5 * mm_per_inch , material_width]);}

  translate(v = [(1.75 * mm_per_inch + material_width) / 2 + tab_width,
                 (1.5 * mm_per_inch),
                 0]){
    rotate(a = 90, v = [0, 0, 1]){
      cube([3 * mm_per_inch, 0.5 * mm_per_inch , material_width]);}}

  translate(v = [(1.75 * mm_per_inch),
                 (1.5 * mm_per_inch + material_width) / 2 - tab_width,
                 0]){
    cube([3 * mm_per_inch, 0.5 * mm_per_inch , material_width]);}}

_4_40 = 0.1285 * mm_per_inch / 2; // size of hole for 4x40
_6_32 = 0.1495 * mm_per_inch / 2; // size of hole for 6x32

module collar_hole(){
  cylinder(h = board_depth, r = 2 * _6_32, $fn = 20);}

module nubbin_hole(){
  cylinder(h = board_depth, r = _6_32, $fn = 20);}

module mounting_screw_hole(){
  cylinder(h = board_depth, r = _6_32, $fn = 20);}

module bracket_screw_hole(){
  cylinder(h = board_depth, r = _6_32, $fn = 20);}

module wheel_motor_holes(scale){
  translate([51 - 26.78, 38 - 10.8, 0] * scale) {
    collar_hole();}
  translate([51 - 26.78, 38 - 22.23, 0] * scale){
    nubbin_hole();}
  translate([51 - 18.05 - 17.45, 38 - 30.81,  0] * scale){
    mounting_screw_hole();}
  translate([51 - 18.05, 38 - 30.81, 0] * scale){
    mounting_screw_hole();}
  translate([7.5, 8.5, 0] * scale){
    bracket_screw_hole();}
  translate([7.5, 21 + 8.5,   0] * scale){
    bracket_screw_hole();}}

module wheel_mount(scale){
  difference(){
    cube(scale * [board_length + material_width,
                  board_width + material_width,
                  material_width]);
    wheel_motor_holes(scale);}}

wheel_mount(1);

translate(v = [0, 0, board_length]) jig_lid();

module jig_lid() {
  union() {
    wheel_mount(1);
    translate(v = [0, -2.1 * material_width, material_width]){
      cube([board_length + material_width,
            3.1 * material_width,
            material_width]);}
    translate(v = [0, -2.1 * material_width, 0]){
      cube([board_length + material_width, material_width, material_width]);}
    translate(v = [-2.1 * material_width, 0, material_width]){
      cube([3.1 * material_width,
            board_width + material_width,
            material_width]);}
    translate(v = [-2.1 * material_width, 0, 0]){
      cube([material_width, board_width+material_width, material_width]);}}}