From 7a0bd02483eb2a3d225392e34037ba8cd7d6131a Mon Sep 17 00:00:00 2001
From: daniel watson <ozzloy@gmail.com>
Date: Tue, 29 Oct 2013 15:17:14 -0700
Subject: [PATCH] make caster flange top half

---
 caster-standoff.scad | 47 +++++++++++++++++++++++---------------------
 1 file changed, 25 insertions(+), 22 deletions(-)

diff --git a/caster-standoff.scad b/caster-standoff.scad
index 27d2ba6..7325c2f 100644
--- a/caster-standoff.scad
+++ b/caster-standoff.scad
@@ -11,7 +11,7 @@ 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 = 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
@@ -76,6 +76,15 @@ module nuts(){
   translate([-standoff_radius, 0, nut_height/2])
     nut(nut_short_side, nut_height);}
 
+module _2_screw (){
+  //measured with calipers
+  screw_height = 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_height, $fn = 20);
+  cylinder(r = head_radius, h = head_height, $fn = 20);}
+
 module caster_standoff(){
   difference(){
     union(){
@@ -86,31 +95,25 @@ module caster_standoff(){
       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, $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_top_half(){
-  difference(){
-    caster_standoff();
-    cylinder(r1 = deck_flange_radius * 4 / 3,
-             r2 = 0,
-             h = standoff_height * 3 / 4);}}
-
-module caster_bottom_half (){
-  difference(){
-    intersection (){
+module caster_standoff_top(){
+  translate([0, 0, caster_flange_height - standoff_height]){
+    difference(){
       caster_standoff();
-      cylinder(r1 = deck_flange_radius * 4 / 3,
-                    r2 = 0,
-                    h = standoff_height * 3 / 4);}
-    // leave a little room for glue
-    translate([0, 0, standoff_height * 3 / 4 - 1]) cylinder(r = 2, h = 2);}}
+      translate([-deck_flange_radius, -deck_flange_radius, -0.1])
+        cube([deck_flange_radius * 2,
+              deck_flange_radius * 2,
+              standoff_height - caster_flange_height + 0.1]);}}}
 
-// move the top half and flip it over for printing
-translate([0, deck_flange_radius + standoff_radius + 1, standoff_height]){
-  rotate([0, 180, 0]){
-    caster_top_half();}}
-caster_bottom_half();
+caster_standoff_top();
-- 
2.30.2