From 5cae2970bf73c03aeefbd4f84d4acc51ba4d28b8 Mon Sep 17 00:00:00 2001
From: =?utf8?q?V=C3=A1clav=20=27Ax=27=20H=C5=AFla?= <axtheb@gmail.com>
Date: Sun, 27 Jan 2013 21:06:39 +0100
Subject: [PATCH] Increasing strength of z axis parts

---
 box_frame/z-axis.scad | 36 +++++++++++++++++++++++-------------
 1 file changed, 23 insertions(+), 13 deletions(-)

diff --git a/box_frame/z-axis.scad b/box_frame/z-axis.scad
index bfd243d..17b6961 100644
--- a/box_frame/z-axis.scad
+++ b/box_frame/z-axis.scad
@@ -32,33 +32,45 @@ module zmotorholder(thickness=20, bottom_thickness=5){
 
 
 module zrodholder(thickness=14, bottom_thickness=5, ylen=42, xlen=34){
+    holder_inner_r = 9;
     difference(){
         union(){
             difference(){
                 union(){
                     //piece along the flat side of a board
-                    cube_fillet([14, ylen, bottom_thickness], vertical=[3, 3, 0, 0]);
+                    cube_fillet([14, ylen, bottom_thickness], vertical=[8, 3, 0, 0]);
                     cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [thickness/1.5, 0, 0, 5]);
                     //hole for Z axis is thru this
-                    cube_fillet([xlen, 14, bottom_thickness], vertical=[0, 0, 0, 3]);
+                    cube_fillet([xlen, 14, bottom_thickness], vertical=[3, 0, 0, 3]);
+                    translate([14,14,0]) {
+                        //large fillet that makes it stiffer by lot. Thanks to Marcus Wolschon
+                        difference(){
+                            cube([holder_inner_r,holder_inner_r,bottom_thickness]);
+                            translate([holder_inner_r, holder_inner_r, -0.5])
+                                cylinder(r=holder_inner_r, h=bottom_thickness + 1);
+                        }
+                    }
                     //piece along cut side of the board
                     if (i_am_box == 1) {
-                        translate([-board_thickness, 0, 0]) cube_fillet([board_thickness + board_to_xz_distance, 5, thickness], radius=2, top = [0, 0, 0, thickness]);
+                        translate([-board_thickness, 0, 0]) 
+                            cube_fillet([board_thickness + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness]);
                     } else {
-                        translate([-board_thickness/2, 0, 0]) cube_fillet([board_thickness/2 + board_to_xz_distance+5, 5, thickness], radius=2, top = [0, 0, 0, thickness]);
+                        translate([-board_thickness/2, 0, 0]) 
+                            cube_fillet([board_thickness/2 + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness]);
                     }
                     //smooth rod insert
                     translate([board_to_xz_distance, 9, 0]) intersection() {
                         cylinder(h=bottom_thickness + layer_height, r=(bushing_z[0] + 5 * single_wall_width));
                         if (bushing_z[0] < 5) {
                             translate([0, -5 , bottom_thickness / 2]) cube([20, 20, bottom_thickness + 10], center=true);
+                            echo(0);
                         } else {
                             translate([0, -bushing_z[0], bottom_thickness / 2]) cube([bushing_z[0] * 4, bushing_z[0] * 4, bottom_thickness + 10], center=true);
                         }
                     }
                 }
                 //smooth rod hole
-                translate([board_to_xz_distance, 9, -1]) cylinder(h=board_thickness+2, r=(bushing_z[0]));
+                translate([board_to_xz_distance, 9, -1]) cylinder_poly(h=board_thickness+2, r=bushing_z[0]);
                 // cutout
                 translate([board_to_xz_distance-1, 5+(bushing_z[0]), 0.4]) cube([2, 10, 100]);
                 //inside rouned corner
@@ -68,26 +80,24 @@ module zrodholder(thickness=14, bottom_thickness=5, ylen=42, xlen=34){
                 //front screws
                 if (i_am_box != 1) {
                     //single plate has both screws on front
-                    translate([17, 35.5, bottom_thickness+4]) rotate([0, -90, 0]) {
-                        screw(head_drop=12, h=122, r_head=4);
+                    translate([16, 35.5, bottom_thickness+4]) rotate([0, -90, 0]) {
+                        screw(head_drop=12, h=122, r_head=4.5);
                     }
-                    translate([17, 15.5, bottom_thickness+4]) rotate([0, -90, 0]) {
-                        screw(head_drop=12, h=122, r_head=4);
+                    translate([16, 15.5, bottom_thickness+4.5]) rotate([0, -90, 0]) {
+                        screw(head_drop=12, h=122, r_head=4.5);
                     }
                 } else {
-                    translate([17, 30, bottom_thickness+4]) rotate([0, -90, 0]) {
+                    translate([16, 30, bottom_thickness+4]) rotate([0, -90, 0]) {
                         screw(head_drop=12, h=122, r_head=4);
                     }
                     //side screw
-                    translate([-board_thickness/2, 0, thickness/2]) rotate([-90, 0, 0]) screw(h=30, r_head=4);
+                    translate([-board_thickness/2, 0, thickness/2]) rotate([-90, 0, 0]) screw(h=30, r_head=4.5, head_drop=1);
                 }
             }
         }
     }
 }
-
 translate([0, -2, 0]) mirror([0, 1, 0]) zmotorholder();
 translate([0, 2, 0]) zmotorholder();
-
 translate([21, -62, 0]) zrodholder();
 translate([20, 62, 0]) mirror([0, 1, 0]) zrodholder();
-- 
2.20.1