From: daniel watson <ozzloy@gmail.com>
Date: Fri, 4 Oct 2013 19:08:09 +0000 (-0700)
Subject: add deck flange with reinforcements
X-Git-Url: http://challenge-bot.com/repos/?p=challenge-bot;a=commitdiff_plain;h=4b158a5e11802098334c8604a7502a07f27ecb90

add deck flange with reinforcements
---

diff --git a/caster-standoff.scad b/caster-standoff.scad
index 41208a9..c855e87 100644
--- a/caster-standoff.scad
+++ b/caster-standoff.scad
@@ -4,23 +4,60 @@
 // https://gitorious.org/ozzloy/challenge-bot
 // https://github.com/waynegramlich/challenge-bot
 
+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
-standoff_radius = 14.732 / 2; // 0.580 / 2 inches from spec sheet
-screw_radius = 2.286/2;  // 0.090 inches
-caster_flange_screw_length = 8; // eyeballed
+
 // eyeballed caster flange height, (0.580/5) inches, times 2 to be stronger
 caster_flange_height = 2.9464 * 2;
 caster_flange_width = 20.32;  // 0.800 inches
-ziptie_width = 4.7625; // 3/16 inch
-ziptie_height = 3; // i'm guessing
+caster_flange_screw_radius = 2.286 / 2;  // 0.090 inches
+caster_flange_screw_length = 8; // eyeballed
+
+deck_grid_width = 25.4; // guessing
+/* setting deck flange values same as caster flange pending
+ * physical testing. */
+deck_flange_height = 2.9464 * 2;
+deck_flange_screw_radius = 2.286 / 2;  // 0.090 inches
+deck_flange_radius = deck_grid_width * 1.5;
+
+module deck_flange(){
+  difference(){
+    cylinder(h = deck_flange_height, r = deck_flange_radius);
+    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,
+             deck_flange_height]){
+    difference (){
+      cube([deck_flange_radius, deck_flange_height, 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 = screw_radius, $fn = 20);
+    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 = screw_radius, $fn = 20);}
+    cylinder(h = caster_flange_screw_length,
+             r = caster_flange_screw_radius,
+             $fn = 20);}
 
 module caster_flange(){
   side_radius = caster_flange_width / 2 - standoff_radius;
@@ -51,6 +88,10 @@ module caster_standoff(){
       scale([1, 1, 1.1])
         caster_flange_screws();
     translate([0, 0, standoff_height - (caster_flange_height + nut_height)])
-      nuts();}}
+      nuts();}
+  deck_flange();
+  for(ii = [0:3]){
+    rotate([0, 0, 45 + 90 * ii])
+      deck_flange_reinforcement();}}
 
 caster_standoff();