// 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 = 15; // i made this up
- 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 fixture(){
- height = 2.9464;
- width = 20.32;
- between = 14.732;
- side_radius = (width - 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 caster_standoff(){
- height = 43;
- caster_radius = 14.732/2;
+standoff_radius = 14.732 / 2; // 0.580 / 2 inches from spec sheet
+standoff_height = 55; // eyeballed
+
+nut_short_side = 4.7; // from calipers
+nut_height = 1.6; // from calipers
+
+// eyeballed caster flange height, (0.580/5) inches, times 2 to be stronger
+caster_flange_height = 5;
+caster_flange_width = 20.32; // 0.800 inches
+caster_flange_screw_radius = 2.286 / 2; // 0.090 inches
+caster_flange_screw_length = 8; // eyeballed
+
+deck_grid_width = 25.4; // measured center to center on grid on pegboard
+deck_flange_height = 2.9464;
+deck_flange_screw_radius = 3.556 / 2; // For #6 machine screws
+deck_flange_radius = deck_grid_width * 1.22;
+
+module deck_flange(){
+ difference(){
+ cylinder(h = deck_flange_height, r = deck_flange_radius, $fn = 50);
+ for(ii = [-1, 1]){
+ translate([deck_grid_width * ii, 0, -.1])
+ cylinder(h = deck_flange_height * 1.1,
+ r = deck_flange_screw_radius,
+ $fn = 20);}
+ for(ii = [-1, 1]){
+ translate([0, deck_grid_width * ii, -.1])
+ cylinder(h = deck_flange_height * 1.1,
+ r = deck_flange_screw_radius,
+ $fn = 20);}}}
+
+module deck_flange_reinforcement(){
+ translate([-deck_flange_radius,
+ -.5 * deck_flange_height / 2,
+ deck_flange_height]){
+ difference (){
+ cube([deck_flange_radius, deck_flange_height / 2, deck_flange_radius]);
+ translate([-.1, -.05 * deck_flange_height, 0]){
+ rotate([0, -45, 0]){
+ cube([deck_flange_radius * 1.5, // 1.5 is bigger than sqrt(2)
+ deck_flange_height * 1.1, // 1.1 is bigger than 1
+ deck_flange_radius]);}}}}}
+
+module caster_flange_screws(){
+ translate([standoff_radius, 0, 0])
+ cylinder(h = caster_flange_screw_length,
+ r = caster_flange_screw_radius,
+ $fn = 20);
+ translate([-standoff_radius, 0, 0])
+ cylinder(h = caster_flange_screw_length,
+ r = caster_flange_screw_radius,
+ $fn = 20);}
+
+module caster_flange(){
+ side_radius = caster_flange_width / 2 - standoff_radius;
+ hull(){
+ cylinder(h = caster_flange_height, r = standoff_radius, $fn = 100);
+ translate([standoff_radius, 0, 0])
+ cylinder(h = caster_flange_height, r = side_radius, $fn = 40);
+ translate([-standoff_radius, 0, 0])
+ cylinder(h = caster_flange_height, r = side_radius, $fn = 40);}}
+
+module nut(size, height){
+ width = size/1.75;
+ for (r = [-60, 0, 60]) rotate([0,0,r]) cube([width, size, height], true);}
+
+module nuts(){
+ translate([standoff_radius, 0, nut_height/2])
+ nut(nut_short_side, nut_height + .1);
+ translate([-standoff_radius, 0, nut_height/2])
+ nut(nut_short_side, nut_height + .1);}
+
+module _2_screw (){
+ //measured with calipers
+ screw_length = 8;
+ thread_radius = 2.17 / 2 - 0.1; // subtract 0.1 to make squeeze fit
+ head_height = 1.8;
+ head_radius = 4.1 / 2;
+ cylinder(r = thread_radius, h = screw_length, $fn = 20);
+ cylinder(r = head_radius, h = head_height, $fn = 20);}
+
+module caster_standoff_deck_side(){
+ difference(){
+ cylinder(h = standoff_height - caster_flange_height,
+ r = standoff_radius,
+ $fn = 50);
+ translate([0, 0, standoff_height - caster_flange_screw_length * 1.1 + 0.1])
+ scale([1, 1, 1.1])
+ caster_flange_screws();
+ translate([0, 0, standoff_height - (caster_flange_height + nut_height)])
+ nuts();
+ translate([0, 0, standoff_height]){
+ // make hole to get to screw head depth
+ cylinder(r = 4.1 / 2, h = 3, center = true, $fn = 20);
+ translate([0, 0, -0.7])
+ rotate([180, 0, 0])
+ _2_screw(r = 0.5, h = 5, $fn = 20);}}
+ deck_flange();
+ for(ii = [0:3]){
+ rotate([0, 0, 45 + 90 * ii])
+ deck_flange_reinforcement();}}
+
+module caster_standoff_caster_side(){
difference(){
- union(){
- cylinder(h = height, r = caster_radius);
- fixture();}
- scale([1, 1, 1.1]) translate([0, 0, -.1]) ball_screws();}}
+ caster_flange();
+ translate([0, 0, caster_flange_height - 0.7]){
+ rotate([180, 0, 0]){
+ _2_screw();}}
+ // make hole to get to screw head
+ translate([0, 0, caster_flange_height - 0.8]){
+ cylinder(r = 4.1 / 2, h = 10, $fn = 20);}
+ translate([0, 0, -.1]){
+ caster_flange_screws();}}}
-caster_standoff();
+caster_standoff_deck_side();
+translate([caster_flange_width / 2 + deck_flange_radius + 1, 0, 0]){
+ caster_standoff_caster_side();}