From 64d38acfb1b07217b104c3f750f7d4f4b6af4e0d Mon Sep 17 00:00:00 2001
From: TQ Hirsch <thequux@thequux.com>
Date: Wed, 23 Feb 2022 22:17:35 +0100
Subject: [PATCH] Finished designing new xsled

---
 assembly.scad  | 20 +----------
 constants.scad | 18 ++++++++++
 parts.scad     | 93 +++++++++++++++++++++++++++++++++++++++++++++++---
 3 files changed, 108 insertions(+), 23 deletions(-)
 create mode 100644 constants.scad

diff --git a/assembly.scad b/assembly.scad
index d2fddd1..9bb06d2 100644
--- a/assembly.scad
+++ b/assembly.scad
@@ -1,22 +1,4 @@
-use_colors = true;
-
-xsize = 450;
-ysize = 400;
-sled_ysize = 7 * 25.4;
-sled_xsize = 8 * 25.4;
-
-xmin = 155;
-ymin = 140;
-// 130..320
-cur_xpos = 155;
-// 140..260
-cur_ypos = 140;
-
-echo(str("Range = ", [ xsize - xmin * 2, ysize - ymin*2 ]));
-
-$fs = 1.5;
-$include_substock = true;
-
+include <constants.scad>;
 include <parts.scad>;
 
 csize = 15;
diff --git a/constants.scad b/constants.scad
new file mode 100644
index 0000000..f8c5705
--- /dev/null
+++ b/constants.scad
@@ -0,0 +1,18 @@
+use_colors = true;
+
+xsize = 450;
+ysize = 400;
+sled_ysize = 7 * 25.4;
+sled_xsize = 8 * 25.4;
+
+xmin = 155;
+ymin = 140;
+// 130..320
+cur_xpos = 155;
+// 140..260
+cur_ypos = 140;
+
+echo(str("Range = ", [ xsize - xmin * 2, ysize - ymin*2 ]));
+
+$fs = 1.5;
+$include_substock = true;
diff --git a/parts.scad b/parts.scad
index 2dc0d08..21b4c2c 100644
--- a/parts.scad
+++ b/parts.scad
@@ -1,4 +1,5 @@
 include <units.inc>;
+include <constants.scad>;
 include <stock_parts.scad>;
 
 frame_size = 20;
@@ -269,6 +270,29 @@ module xsled_frame() {
 }
 
 module xsled2() {
+
+
+  tab_len = bushing_len * 2;
+  tab_thickness = bushing_od + wall_thickness * 2;
+  glass_thickness = 3; // TODO: Update when an actual size is available
+
+  inner_ysize = sled_ysize - tab_thickness;
+
+  lip_depth = tab_thickness - wall_thickness - glass_thickness;
+  lip_width = glass_thickness;
+
+  glass_holder_points = [
+    [0,0],
+    [lip_depth + wall_thickness, 0],
+    [lip_depth + wall_thickness, wall_thickness + 0.5],
+    [lip_depth, wall_thickness + 0.5],
+    [lip_depth, wall_thickness + glass_thickness],
+    [lip_depth - glass_thickness, wall_thickness + glass_thickness],
+    [lip_depth - glass_thickness, wall_thickness + glass_thickness*2],
+    [0, tab_thickness]
+  ];
+
+
   for (xsign = [1,-1],
 	 ysign = [1,-1]) {
     translate([sled_xsize / 2 * xsign,
@@ -276,11 +300,72 @@ module xsled2() {
 		0])
     rotate([0, -90 * xsign, 0]) {
       difference() {
-	cylinder(d = bushing_od + wall_thickness, h = bushing_len + wall_thickness);
-	cylinder(d = rail_diam + 1 , h = (bushing_len + wall_thickness + 1) * 2,
-		 center = true);
+        union() {
+          cylinder(d = tab_thickness, h = tab_len);
+          translate([-tab_thickness/2,
+                      ysign > 0 ? -tab_thickness/2: 0,
+                      0])
+          cube([tab_thickness, tab_thickness/2, tab_len]);    
+        }
+        translate([0,0,-0.5]) {
+        	cylinder(d = bushing_od, h = bushing_len+0.5);
+          cylinder(d = rail_diam * 1.1 , h = tab_len + 1);
+        }
       }
-      bushing();
+      if ($preview) {
+        bushing();
+      }
+    }
+
+    //cube([sled_xsize, inner_ysize, tab_thickness/2], center=true);
+    difference() {
+      union() {
+        translate([-sled_xsize/2, -inner_ysize/2, -tab_thickness/2])
+        rotate([0, 90, 0])
+        rotate([0,0,90])
+        linear_extrude(sled_xsize)
+        polygon(glass_holder_points);
+
+        translate([sled_xsize/2, inner_ysize/2, -tab_thickness/2])
+        rotate([0, 90, 180])
+        rotate([0,0,90])
+        linear_extrude(sled_xsize)
+        polygon(glass_holder_points);
+
+        translate([sled_xsize/2, -inner_ysize/2, -tab_thickness/2])
+        rotate([0, 90, 90])
+        rotate([0,0,90])
+        linear_extrude(inner_ysize)
+        polygon(glass_holder_points);
+
+        translate([-sled_xsize/2, inner_ysize/2, -tab_thickness/2])
+        rotate([0, 90, -90])
+        rotate([0,0,90])
+        linear_extrude(inner_ysize)
+        polygon(glass_holder_points);
+      }
+
+      translate([-10, inner_ysize/2 - 1 - lip_depth + glass_thickness, -tab_thickness/2 + wall_thickness + glass_thickness])
+      cube([20, glass_thickness + 1, 30]);
     }
   }
+
+  color("#fff3")
+  if ($preview) {
+    // draw glass sheets
+    translate([0,0,-tab_thickness/2 + wall_thickness + glass_thickness/2])
+    cube([sled_xsize - lip_depth*2, inner_ysize - lip_depth*2, glass_thickness],
+      center=true);
+    translate([0,0,-tab_thickness/2 + wall_thickness + 3*glass_thickness/2])
+    cube(
+      [
+        sled_xsize - lip_depth*2 + glass_thickness*2,
+        inner_ysize - lip_depth*2 + glass_thickness*2, 
+        glass_thickness
+      ],
+      center=true);
+    
+  }
 }
+// render()
+//xsled2();