From 578046a141066f45967036eb2ef683ce2d661b3c Mon Sep 17 00:00:00 2001
From: "Jan \"Yenya\" Kasprzak" <kas@fi.muni.cz>
Date: Thu, 4 Feb 2021 10:47:21 +0100
Subject: [PATCH] quasar-fw next gen

---
 quasar-firewall.scad | 135 +++++++++++++++++++++++++------------------
 1 file changed, 78 insertions(+), 57 deletions(-)

diff --git a/quasar-firewall.scad b/quasar-firewall.scad
index 3f95374..83a68bf 100644
--- a/quasar-firewall.scad
+++ b/quasar-firewall.scad
@@ -1,81 +1,102 @@
 eps = 0.01;
 infty = 100;
 
-base_d = 20;
+wall = 1.2;
+base_wall = 5; // before the cut to the angles
+real_base_wall = 1.5; // after the cut
 
-wall = 1.5;
-base_wall = 2.5;
+angle_horiz = 2; // y axis is horizontal, so this is rotate along x
+angle_vert = 1;  // x axis is vertical, so this is rotate along y
 
-center_d = 8 + 0.3;
+center_hole = 8 + 0.3;
+center_d = 24;
 
 foam_horiz = 6 + 0.3;
-foam_vert = 6 + 0.6;
-support_h = 50;
-
-top_d = foam_horiz + 8;
 side_w = 40;
 
+wing_clip_w1 = 9;
+wing_clip_w2 = 8;
+wing_clip_h = 20;
+wing_clip_top_off = 5;
+
 screw_dist = 31.5;
-screw_d = 3;
+screw_d = 2;
 
-// half of the diamond diagonals
-diamond_x = 12;
-diamond_y = 32;
-diamond_wall_h = 4;
-diamond_x1 = 9;
-diamond_y1 = 27;
-diamond_x2 = 7;
-diamond_y2 = 21;
+fuse_w = 18;
+fuse_h = 52;
+fuse_add = 2;
+fuse_top = 2;
 
-module body() {
-	// base circle
-	cylinder(r = base_d/2, h = base_wall);
-	// diamond front
-	scale([1, diamond_y/diamond_x, 1])
-		cylinder(r = diamond_x, h = base_wall, $fn = 4); 
-	difference() {
-		scale([1, diamond_y1/diamond_x1, 1])
-			cylinder(r = diamond_x1, h = base_wall + diamond_wall_h, $fn = 4); 
-		translate([0, 0, base_wall])
-		scale([1, diamond_y2/diamond_x2, 1])
-			cylinder(r = diamond_x2, h = diamond_wall_h+eps, $fn = 4); 
-	}
+module body_solid() {
+	cylinder(r = center_d/2, h = base_wall);
 	// wing front
 	translate([-side_w/2, -foam_horiz/2-wall, 0])
 		cube([side_w, foam_horiz+2*wall, base_wall]);
+	// wing clips on sides
 	for (x = [-1, 1]) scale([x, 1, 1])
 		hull() {
-			translate([base_d/2, -foam_horiz/2-wall, 0])
-				cube([side_w/2-base_d/2, foam_horiz+2*wall, eps]);
-			translate([base_d*.9, -foam_horiz/2-wall, 20])
-				cube([side_w/2-base_d*.55, foam_horiz+2*wall, eps]);
+			// bottom
+			translate([side_w/2-wing_clip_w1, -foam_horiz/2-wall, 0])
+				cube([wing_clip_w1, foam_horiz+2*wall, eps]);
+			// top
+			translate([side_w/2-wing_clip_w1+wing_clip_top_off,
+				-foam_horiz/2-wall, wing_clip_h])
+				cube([wing_clip_w1, foam_horiz+2*wall, eps]);
 		}
+	// fuse front
+	hull() {
+		for (x = [-1, 1]) scale([x, 1, 1])
+			translate([fuse_w/2, 0, 0])
+			cylinder(r = fuse_add, h = base_wall, $fn = 16);
+		for (y = [-1, 1]) scale([1, y, 1])
+			translate([0, fuse_h/2, 0])
+			cylinder(r = fuse_add, h = base_wall, $fn = 16);
+	}
+	// fuse clips body
+	hull() for (x = [-1, 1]) for (y = [-1, 1]) scale([x, y, 1]) {
+		translate([fuse_w/2, 0, 0])
+			cylinder(r = eps, h = base_wall + fuse_top, $fn = 4);
+		translate([0, fuse_h/2, 0])
+			cylinder(r = eps, h = base_wall + fuse_top, $fn = 4);
+	}
 }
 
-difference() {
-	body();
-	// screw holes
-	for (angle = [0:90:360])
-		rotate([0, 0, angle])
-		translate([screw_dist/2, 0, -eps])
-		cylinder(r = screw_d/2, h = base_wall + 2*eps);
-	// tube hole
-	translate([0, 0, -eps])
-		cylinder(r = center_d/2, h = base_wall + 2*eps);
-	// horizontal foam
+module body_diff() {
 	difference() {
-		translate([-infty/2, -foam_horiz/2, base_wall])
-			cube([infty, foam_horiz, support_h + eps]);
-		translate([-diamond_x1, 0, base_wall])
-			cube([2*diamond_x1, foam_horiz/2, support_h + eps]);
+		body_solid();
+		// center hole
+		translate([0, 0, -eps])
+			cylinder(r = center_hole/2, h = base_wall + 2*eps);
+		// horizontal foam
+		difference() {
+			translate([-infty/2, -foam_horiz/2, base_wall])
+				cube([infty, foam_horiz, infty]);
+			// in the center there is only bottom half of the foam
+			translate([-fuse_w/2, 0, base_wall-eps])
+				cube([fuse_w, foam_horiz/2, infty]);
+		}
+		// screw holes
+		for (angle = [0:90:360])
+			rotate([0, 0, angle])
+			translate([screw_dist/2, 0, -eps])
+			cylinder(r = screw_d/2, h = base_wall + 2*eps);
+		// fuse clips inside
+		hull() for (x = [-1, 1]) for (y = [-1, 1]) scale([x, y, 1]) {
+			translate([fuse_w/2 - wall/sin(atan(fuse_h/fuse_w)), 0, base_wall])
+				cylinder(r = eps, h = base_wall + fuse_top, $fn = 4);
+			translate([0, fuse_h/2 - wall/sin(atan(fuse_w/fuse_h)), base_wall])
+				cylinder(r = eps, h = base_wall + fuse_top, $fn = 4);
+		}
 	}
-	// cable hole
-	translate([6, 6, -eps])
-		rotate([0, 0, -45])
-		scale([1, 1/2, 1])
-		cylinder(r = 4, h = support_h + base_wall + 2*eps);
-	// vertical foam
-	// translate([-foam_vert/2, -side_w/2-eps, base_wall])
-	// 	cube([foam_vert, side_w + 2*eps, support_h + eps]);
+}
+
+// now rotate it and cut the bottom
+difference() {
+	rotate([0, angle_horiz, 0])
+	rotate([angle_vert, 0, 0])
+	translate([0, 0, real_base_wall - base_wall])
+		body_diff();
+	translate([-infty/2, -infty/2, -infty])
+		cube(infty);
 }
 
-- 
2.43.0