// https://gitorious.org/ozzloy/challenge-bot
// https://github.com/waynegramlich/challenge-bot
+// use 10 ish for development, 60 or so for printing
+$fn = 60;
+
standoff_radius = 14.732 / 2; // 0.580 / 2 inches from spec sheet
standoff_height = 55; // eyeballed
nut_height = 1.6; // from calipers
// eyeballed caster flange height, (0.580/5) inches, times 2 to be stronger
-caster_flange_height = 2.9464;
+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;
+deck_flange_radius = (deck_grid_width) / 2 + deck_flange_screw_radius + 3;
module deck_flange(){
difference(){
cylinder(h = deck_flange_height, r = deck_flange_radius);
for(ii = [-1, 1]){
- translate([deck_grid_width * ii, 0, -.1])
+ translate([deck_grid_width / 2 * 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])
+ r = deck_flange_screw_radius);
+ translate([0, deck_grid_width / 2 * ii, -.1])
cylinder(h = deck_flange_height * 1.1,
- r = deck_flange_screw_radius,
- $fn = 20);}}}
+ r = deck_flange_screw_radius);}}}
module deck_flange_reinforcement(){
translate([-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);
+ r = caster_flange_screw_radius);
translate([-standoff_radius, 0, 0])
cylinder(h = caster_flange_screw_length,
- r = caster_flange_screw_radius,
- $fn = 20);}
+ r = caster_flange_screw_radius);}
module caster_flange(){
side_radius = caster_flange_width / 2 - standoff_radius;
module nuts(){
translate([standoff_radius, 0, nut_height/2])
- nut(nut_short_side, nut_height);
+ nut(nut_short_side, nut_height + .1);
translate([-standoff_radius, 0, nut_height/2])
- nut(nut_short_side, nut_height);}
+ nut(nut_short_side, nut_height + .1);}
-module caster_standoff(){
+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);
+ cylinder(r = head_radius, h = head_height);}
+
+module caster_standoff_deck_side(){
difference(){
- union(){
- cylinder(h = standoff_height, r = standoff_radius);
- translate([0, 0, standoff_height - caster_flange_height])
- caster_flange();}
+ cylinder(h = standoff_height - caster_flange_height,
+ r = standoff_radius);
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();}
+ nuts();
+ translate([0, 0, standoff_height]){
+ // make hole to get to screw head depth
+ cylinder(r = 4.1 / 2, h = 3, center = true);
+ translate([0, 0, -0.7])
+ rotate([180, 0, 0])
+ _2_screw(r = 0.5, h = 5);}}
deck_flange();
for(ii = [0:3]){
rotate([0, 0, 45 + 90 * ii])
deck_flange_reinforcement();}}
-module caster_top_half(){
+module caster_standoff_caster_side(){
difference(){
- caster_standoff();
- cylinder(r1 = deck_flange_radius * 4 / 3,
- r2 = 0,
- h = standoff_height * 3 / 4);}}
-
-module caster_bottom_half (){
- intersection (){
- caster_standoff();
- cylinder(r1 = deck_flange_radius * 4 / 3,
- r2 = 0,
- h = standoff_height * 3 / 4);}}
+ 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);}
+ translate([0, 0, -.1]){
+ caster_flange_screws();}}}
-translate([0, deck_flange_radius + standoff_radius + 1, standoff_height]){
- rotate([0, 180, 0]){
- caster_top_half();}}
-difference(){
- caster_bottom_half();
- translate([0, 0, standoff_height * 3 / 4 - 1]) cylinder(r = 2, h = 2);}
+caster_standoff_deck_side();
+translate([caster_flange_width / 2 + deck_flange_radius + 1, 0, 0]){
+ caster_standoff_caster_side();}