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Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

Day: April 13, 2012

  • Wouxun KG-UV3D GPS Interface: Functional Case

    Rebuilding the case with some improvements  to the original design came out much better:

    HT-GPS Case - Wouxun KG-UV3D side view
    HT-GPS Case – Wouxun KG-UV3D side view

    The latch is about the same as before, but the top endplate now has two cable ports and locating pins to take the force from the battery contact springs:

    HT-GPS Case - latch detail
    HT-GPS Case – latch detail

    The bottom endplate has a hole for the TinyTrak3 Mode switch, plus two locating pins that hold the plate in place:

    HT-GPS Case - Wouxun KG-UV3D base view
    HT-GPS Case – Wouxun KG-UV3D base view

    A detail shot of the two endplates shows the new holes:

    HT-GPS Case - endplate detail
    HT-GPS Case – endplate detail

    Snippets of brass rod became locating pins, each slipped into a hole atop a dab of epoxy to lock it in place:

    HT-GPS Case - locating pin detail
    HT-GPS Case – locating pin detail

    The boards slide in pretty much the way you’d expect:

    HT-GPS Case - Trial fit - rear view
    HT-GPS Case – Trial fit – rear view

    The OpenSCAD code punches a third cable hole in the case for the HT wiring. I had high hopes that it would fit through the endplate, but …

    Seen from the other end, there’s not much to see. The next case will have a slightly narrower LED opening:

    HT-GPS Case - Trial fit - base view
    HT-GPS Case – Trial fit – base view

    The imperfection running down the side comes from a brief pause in the proceedings while the support plate fell out of the opening. As a consequence, I discovered that the LED window doesn’t need any support at all.

    This view shows one of the battery contacts peeking through the hole for a yet-to-be-made stud:

    HT-GPS Case - Wouxun KG-UV3D rear view
    HT-GPS Case – Wouxun KG-UV3D rear view

    The solid model show some additional revisions, but it’s pretty close to the green plastic versions:

    HT-GPS Case - holes and pins - solid model
    HT-GPS Case – holes and pins – solid model

    The OpenSCAD source code:

    // Wouxun KB-UV3D Battery Pack Case
    // Ed Nisley KE4ZNU April 2012
    
    include </home/ed/Thing-O-Matic/lib/MCAD/units.scad>
    include </home/ed/Thing-O-Matic/Useful Sizes.scad>
    
    // Layout options
    
    Layout = "Fit";
    					// Overall layout: Fit Show
    					// Printing plates: Build1 .. Buildn (see bottom!)
    					// Parts: TT3 Audio DSub Shell Base Top
    					// Shapes: RadioBase Contact
    					// Speaker-mic mount: PlugPlate
    
    ShowGap = 20;		// spacing between parts in Show layout
    
    //- Extrusion parameters must match reality!
    //  Print with +1 shells and 3 solid layers
    
    ThreadThick = 0.25;
    ThreadWidth = 2.0 * ThreadThick;
    
    HoleWindage = 0.2;
    
    function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
    
    Protrusion = 0.1;			// make holes end cleanly
    
    //----------------------
    //- Dimensions
    
    CaseOverallHeight = 31.5;				// from battery surface, must clear PCBs!
    CaseOverallWidth = 56;
    CaseOverallLength = 80.25;				// inside of base to end of compartment
    
    BatteryClearance = 1.5;					// contact seal height = air gap to compartment
    
    // Interface to radio battery contacts
    //	Length = shell length
    //		calculated after everything else, so as to fill the compartment
    
    PlateWidthMin = 53.0;
    PlateWidthMax = 54.5;
    PlateThick = IntegerMultiple(2.0,ThreadThick);
    PlateAngle = atan(PlateThick/(PlateWidthMax/2 - PlateWidthMin/2));
    
    ContactDia = 7.0;				// use rounded contact for simplicity
    ContactRecess = IntegerMultiple(0.5,ThreadThick);	// recess for contact plate
    ContactGapX = 10.5;				// X space between contacts
    Contact1Y = 52.5;				// offset from base to edge of contact
    Contact2Y = 56.5;
    ContactStudDia = Clear4_40;
    ContactStudHead = Head4_40;
    ContactStudHeadThick = Head4_40Thick;
    
    // Offsets from battery surface to PCB centerlines
    //	TT3 must be above HT back shell for DB9 clearance
    //	These must cooperate with the numbers in the case shell module
    
    TT3Offset = 17.5 + PlateThick;
    AudioOffset = 4.0 + PlateThick;
    
    // Plate interface to base alignment holes and notches
    
    BaseWidthInner = PlateWidthMin;
    BaseWidthOuter = CaseOverallWidth;
    BaseLength = CaseOverallHeight;					// perpendicular to battery surface
    BaseThick = IntegerMultiple(1.0,ThreadThick);	// minimum sheet thickness below teeth
    BaseWidthTaper = 5.0;							// ramp across entire width
    
    BaseOpeningMax = 43.0;
    BaseOpeningMin = 33.0;
    BaseOpeningY = 5.3;
    BaseOpeningDepth = IntegerMultiple(2.25,ThreadThick);
    
    BaseTotalThick = BaseThick + BaseOpeningDepth;
    echo("Base min thick: ",BaseThick," total: " ,BaseTotalThick);
    
    BaseTabWidth = 6.0;
    BaseTabThick = 2.0;
    BaseTabGap = 7.0;
    BaseTabOC = BaseTabWidth + BaseTabGap;
    BaseToothSection = 3*BaseTabWidth + 2*BaseTabGap;
    
    BaseToothBase = 5.8;
    BaseToothTip = 2.8;
    BaseToothThick = 2.0;
    BaseToothAngle = atan(BaseOpeningDepth/0.6);
    BaseToothOC = BaseTabOC;
    
    WedgeAngle = atan(BaseWidthTaper/((BaseWidthOuter - BaseWidthInner)/2));
    
    BaseEndLip = ThreadThick;			// should be 0.25 mm or so
    BaseEndWidth = (PlateWidthMin - 3*BaseToothBase - 2*BaseToothTip)/2;
    BaseEndAngle = atan((BaseOpeningDepth - BaseEndLip)/BaseOpeningY);
    
    SwitchBody = [8.6,3.7,3.3];			// mode switch
    
    // Plate interface to HT battery latch, cables, and connectors
    
    TopThick = IntegerMultiple(5.5,ThreadThick);	// plate thickness for stiffness behind latch bar
    echo("Top plate thick: ",TopThick);
    
    DB9Recess = TopThick - 4.0;			// recess to max TT3 PCB clearance behind DB9 plate
    
    TabEngageLength = 1.6;				// tab engaging surface length
    TabWidth = 3.0;						//  ... width
    TabEngageHeight = 4.5;				//  ... above battery compartment floor
    TabHeight = 7.5;					// tab ramp top above battery compartment floor
    TabOC = 40.0;
    
    LatchBarWidth = 3.4;				// sliding latch mechanism (brass L stock)
    LatchBarDepth = 3.4;
    LatchBarThick = 0.35;
    
    echo(" ... minimum: ",TopThick - LatchBarDepth);
    
    SplitOffset = TT3Offset - 3.5;
    
    TopBevel = 1.0;						// bevel at top of battery compartment
    TopBevelAngle = 45;
    
    PinOffsetWidth = 2.5;				// choose to center in sides of case shell
    PinOffsetHeight = 12.0;				// above baseplate bottom
    PinDepth = 7.0;						// into case shell
    PinDia = 1.2;
    
    ShellLength = CaseOverallLength - BaseThick - TopThick;
    
    echo("Shell length: ",ShellLength);
    
    // Speaker-mic plug plate
    
    PlugBaseThick = 2.5;				// recess depth
    PlugFillThick = 3.0;				// outer plate thickness
    
    //----------------------
    // Useful routines
    
    module PolyCyl(Dia,Height,ForceSides=0) {			// based on nophead's polyholes
    
      Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
    
      FixDia = Dia / cos(180/Sides);
    
      cylinder(r=(FixDia + HoleWindage)/2,
               h=Height,
    	   $fn=Sides);
    }
    
    module ShowPegGrid(Space = 10.0,Size = 1.0) {
    
      Range = floor(50 / Space);
    
    	for (x=[-Range:Range])
    	  for (y=[-Range:Range])
    		translate([x*Space,y*Space,Size/2])
    		  %cube(Size,center=true);
    
    }
    
    //-------------------
    // Component parts
    
    //-----
    // TinyTrak3+ PCB and component envelope
    //	Some dimensions should feed into the case shell, but don't
    
    module TinyTrak3(Length = 1.0) {
    
    PCBThick = 1.6;
    PCBWide = 36.5;
    TopHigh = 9.5;
    TopWide = PCBWide - 1.5;
    BotHigh = 2.5;
    BotWide = 35.0;
    
    PCBx = PCBWide/2;
    PCBy = (PCBThick + HoleWindage)/2;
    URx = TopWide/2;
    URy = PCBy + TopHigh;
    LRx = BotWide/2;
    LRy = PCBy + BotHigh;
    
      linear_extrude(height=Length,center=false,convexity=2) {
    	polygon(points=[[URx,URy],[URx,PCBy],[PCBx,PCBy],[PCBx,-PCBy],[LRx,-PCBy],[LRx,-LRy],
    					[-LRx,-LRy],[-LRx,-PCBy],[-PCBx,-PCBy],[-PCBx,PCBy],[-URx,PCBy],[-URx,URy]
    				   ]);
      }
    }
    
    //-----
    // Interface PCB and component envelope
    //	Some dimensions should feed into the case shell, but don't
    
    module AudioInterface(Length = 1.0) {
    
    PCBThick = 2.0;
    PCBWide = 49.5;
    TopHigh = 9.0 + Protrusion;
    TopWide = 46.0;
    BotHigh = 3.0;
    BotWide = 44.0;
    
    PCBx = PCBWide/2;
    PCBy = (PCBThick + HoleWindage)/2;
    URx = TopWide/2;
    URy = PCBy + TopHigh;
    LRx = BotWide/2;
    LRy = PCBy + BotHigh;
    
      linear_extrude(height=Length,center=false,convexity=2) {
    	polygon(points=[[URx,URy],[URx,PCBy],[PCBx,PCBy],[PCBx,-PCBy],[LRx,-PCBy],[LRx,-LRy],
    					[-LRx,-LRy],[-LRx,-PCBy],[-PCBx,-PCBy],[-PCBx,PCBy],[-URx,PCBy],[-URx,URy]
    				   ]);
      }
    }
    
    //-----
    // DB-9 (DE-9) panel opening
    // http://www.interfacebus.com/Connector_D-Sub_Mechanical_Dimensions.html
    //  DB-9 shell mounts on outside surface of case
    // This is for the solder terminal side
    
    module DSubMin9(Length = 1.0) {
    
    Holex = 0.984/2 * inch;
    HoleDia = Tap4_40;
    
    URx = 0.769/2 * inch;
    URy = 0.432/2 * inch;
    
    	linear_extrude(height=Length,center=false,convexity=3) {
    	  polygon(points=[[URx,URy],[URx,-URy],[-URx,-URy],[-URx,URy]]);
    	  for (x = [-1,1]) {
    		translate([x*Holex,0,0])
    		  rotate(45) circle(r=(HoleDia + HoleWindage)/2,$fn=4);
    	  }
    	}
    
    }
    
    //-----
    // Central case shape
    //	This *should* depend directly on the circuit board sizes, but doesn't
    //	The "Offset" parameters attempt to bottle up all the board sizes
    //	Support in LED window must be hand-fit to work correctly... and isn't needed!
    
    module CaseShell(Length=(ShellLength),Holes="true") {
    
    // Polygon coordinates are in XY plane
    
    URx = 40.0/2;
    URy = CaseOverallHeight;
    
    MRx = CaseOverallWidth/2;
    MRy = 15.0;
    
    LRx = CaseOverallWidth/2;
    LRy = (LRx - PlateWidthMin/2)*tan(PlateAngle);
    
    BRx = PlateWidthMax/2;
    BRy = PlateThick - 0*Protrusion;
    
    PRx = PlateWidthMin/2;				// combined battery plate
    PRy = 0;
    
    ScrewOffset = 20.0;					// from top end of case
    
    LEDWindow = [30.0,5.0,6];			// with case aligned vertically
    LEDOffset = [15,URy,(Length + TopThick - 25.0)];
    
    TrimPot1 = [-14,TT3Offset,(Length + TopThick - 30)];
    TrimPot2 = [-14,TT3Offset,(Length + TopThick - 37.5)];
    
    HTCableDia = 3.2;
    HTCableOffset = AudioOffset + HTCableDia/2 + 1.0;
    
      rotate([90,0,180])
    	union() {
    	  difference() {
    
    		  linear_extrude(height=Length,center=false,convexity=5)
    			polygon(points=[[URx,URy],[MRx,MRy],[LRx,LRy],[BRx,BRy],[PRx,PRy],
    							[-PRx,PRy],[-BRx,BRy],[-LRx,LRy],[-MRx,MRy],[-URx,URy]]);
    
    		if (Holes) {
    		  translate([0,AudioOffset,-Protrusion])
    			AudioInterface(Length + 2*Protrusion);
    
    		  translate([0,TT3Offset,-Protrusion])
    			TinyTrak3(Length + 2*Protrusion);
    
    		  for (y = [TT3Offset,AudioOffset])
    			translate([-CaseOverallWidth,y,(Length - ScrewOffset)])
    			  rotate([0,90,0])
    				rotate(0)					// Z rotation puts point upward for printing
    				PolyCyl(Tap4_40,CaseOverallWidth);
    
    		  translate(LEDOffset)
    			rotate([90,90,0])
    			  translate([-LEDWindow[0]/2,-LEDWindow[1]/2,-Protrusion])
    			  cube(LEDWindow,center=false);
    
    		  for (p = [TrimPot1,TrimPot2])
    			translate(p)
    			  rotate([-90,90,0])				// Y rotation puts point upward for printing
    				PolyCyl(3.0,URy);
    
    		  for (x=[-1,1]) {
    			translate([x*(CaseOverallWidth/2 - PinOffsetWidth),
    					  PinOffsetHeight,
    					  (Length - PinDepth)])
    			  rotate(45)						// align hole sides with case sides
    				  PolyCyl(PinDia,2*TopThick);
    			translate([x*(CaseOverallWidth/2 - PinOffsetWidth),
    					  PinOffsetHeight,
    					  -PlateThick])
    			  rotate(45)						// align hole sides with case sides
    				  PolyCyl(PinDia,(PlateThick + PinDepth));
    		  }
    
    		  translate([-(ContactGapX/2 + ContactDia/2),0,(Contact1Y + ContactDia/2)])
    			rotate([90,0,0])
    			  Contact();
    		  translate([+(ContactGapX/2 + ContactDia/2),0,(Contact2Y + ContactDia/2)])
    			rotate([90,0,0])
    			  Contact();
    
    		  translate([CaseOverallWidth/2,HTCableOffset,(Length - HTCableDia/2)])
    			rotate([0,90,0])
    			  cube([(HTCableDia + Protrusion),HTCableDia,CaseOverallWidth],center=true);
    		}
    	  }
    
    if (false)
    	  if (Holes)
    		translate(LEDOffset)						// support plug in LED window
    		  rotate([90,90,0])
    			translate([-0.95*LEDWindow[0]/2,-0.80*LEDWindow[1]/2,ThreadWidth/2])
    			  cube([0.95*LEDWindow[0],0.80*LEDWindow[1],2*ThreadWidth],center=false);
    
    	}
    
    }
    
    //-----
    // Battery contact recess
    //  This gets subtracted from the bottom plate in two places
    // 	Align points to print upward
    
    module Contact() {
    
    if (true)
      union() {													// vertical printing with case
    	translate([0,0,-(ContactRecess + Protrusion)/2])
    	  PolyCyl(ContactDia,(ContactRecess + Protrusion),8);
    	translate([0,0,-(PlateThick + Protrusion)])
    	  rotate(60/2)
    	  PolyCyl(ContactStudDia,PlateThick,6);
    	translate([0,0,-(ContactRecess + ContactStudHeadThick/3)])
    	  PolyCyl(ContactStudHead,ContactStudHeadThick,8);				// allow for solder blob
      }
    else
        union() {												// horizontal printing alone
    	translate([0,0,-(ContactRecess - Protrusion)/2])
    	  PolyCyl(ContactDia,(ContactRecess + Protrusion),8);
    	translate([0,0,-(PlateThick + Protrusion)])
    	  PolyCyl(ContactStudDia,(PlateThick + 2*Protrusion));
    	translate([0,0,-(ContactRecess + ContactStudHeadThick/3)])
    	  PolyCyl(ContactStudHead,ContactStudHeadThick,8);				// allow for solder blob
      }
    
    }
    
    //-----
    // Radio bottom locating feature
    //  This polygon gets subtracted from the battery pack base
    
    module RadioBase() {
    
    linear_extrude(height=(BaseOpeningDepth + Protrusion),center=false,convexity=5)
      polygon(points=[
    			[-BaseOpeningMax/2,-Protrusion],
    
    			[-BaseOpeningMin/2,BaseOpeningY],
    			[-(BaseToothOC/2 + BaseToothBase/2),BaseOpeningY],
    
    			[-(BaseToothOC/2 + BaseToothTip/2),(BaseOpeningY - BaseToothThick)],
    			[-(BaseToothOC/2 - BaseToothTip/2),(BaseOpeningY - BaseToothThick)],
    			[-(BaseToothOC/2 - BaseToothBase/2),BaseOpeningY],
    
    			[ (BaseToothOC/2 - BaseToothBase/2),BaseOpeningY],
    			[ (BaseToothOC/2 - BaseToothTip/2),(BaseOpeningY - BaseToothThick)],
    			[ (BaseToothOC/2 + BaseToothTip/2),(BaseOpeningY - BaseToothThick)],
    			[ (BaseToothOC/2 + BaseToothBase/2),BaseOpeningY],
    			[ BaseOpeningMin/2,BaseOpeningY],
    
    			[ BaseOpeningMax/2,-Protrusion],
    
    			[ (BaseTabOC + BaseTabWidth/2),-Protrusion],
    			[ (BaseTabOC + BaseTabWidth/2),BaseTabThick],
    			[ (BaseTabOC - BaseTabWidth/2),BaseTabThick],
    			[ (BaseTabOC - BaseTabWidth/2),-Protrusion],
    
    			[ BaseTabWidth/2,-Protrusion],
    			[ BaseTabWidth/2,BaseTabThick],
    			[-BaseTabWidth/2,BaseTabThick],
    			[-BaseTabWidth/2,-Protrusion],
    
    			[-(BaseTabOC + BaseTabWidth/2),-Protrusion],
    			[-(BaseTabOC + BaseTabWidth/2),BaseTabThick],
    			[-(BaseTabOC - BaseTabWidth/2),BaseTabThick],
    			[-(BaseTabOC - BaseTabWidth/2),-Protrusion],
    		  ],
    		  convexity=5
      );
    }
    
    //-----
    // Battery pack base
    
    module Base() {
    
      difference() {
    
    	rotate([-90,180,0])
    	  CaseShell(BaseTotalThick,false);
    
    	translate([0,0,BaseThick])
    	  RadioBase();
    
    	translate([-BaseWidthOuter,-(BaseThick + BaseEndLip)/tan(BaseEndAngle),0])
    	  rotate([BaseEndAngle,0,0])
    		difference() {
    		  cube([2*BaseWidthOuter,3*BaseOpeningY,BaseOpeningDepth],center=false);
    		  translate([(BaseWidthOuter - (BaseToothSection + 2*Protrusion)/2),0,0])
    			cube([(BaseToothSection + 2*Protrusion),1.2*BaseOpeningY,BaseOpeningDepth],center=false);
    		}
    
    	translate([0,0,BaseThick])
    	  rotate([(-90 + BaseToothAngle),0,0])
    		translate([0,-0.5,0])
    		  cube([(BaseToothSection + 2*Protrusion),1.0,10],center=true);
    
    	for (x=[-1,1])
    	  translate([x*(CaseOverallWidth/2 - PinOffsetWidth),PinOffsetHeight,-Protrusion])
    		rotate(45)						// align hole side with plate side
    		  PolyCyl(PinDia,2*TopThick);
    
    	translate([(-SwitchBody[0]/2),TT3Offset,-SwitchBody[2]/2])
    	  scale([1,1,2])
    		cube(SwitchBody);
    
      }
    }
    
    //-----
    // Top plate with latch
    //	Split around TinyTrak3 serial connector
    //	 ... which must be at the same height as in the shell!
    //	The cable hole sizes & locations are entirely ad-hoc
    
    module TopPlate() {
    
    Cable1Dia = 5.0;
    Cable2Dia = 5.0;
    CableHoleLength = TopThick + 2*Protrusion;
    CableHoleZ = -Protrusion;
    
    DB9Plate = [32.0,13.5,1.25];					// plate surrounding connector body
    
      difference() {
    
    	rotate([-90,180,180])
    	  CaseShell(TopThick,false);
    
    	translate([0,-TT3Offset,-Protrusion])
    	  DSubMin9(TopThick + 2*Protrusion);
    
    	translate([0,-TT3Offset,(TopThick - DB9Plate[2]/2)])
    	  cube([DB9Plate[0],DB9Plate[1],(DB9Plate[2] + Protrusion)],center=true);
    
    	translate([-CaseOverallWidth,-SplitOffset,-2*Protrusion])		// split the plate
    	  cube([2*CaseOverallWidth,4*Protrusion,(TopThick + 2*Protrusion)]);
    
    	translate([0,0,(TopThick - TopBevel)])
    	  rotate([-TopBevelAngle,0,0])
    		translate([-CaseOverallWidth,-TopThick,0])
    		  cube([2*CaseOverallWidth,2*TopThick,2*TopThick],center=false);
    
    	for (x=[-1,1])
    	  translate([(x*TabOC/2),
    				(-TabHeight/2 + Protrusion),
    				(TopThick - TabEngageLength/2 + Protrusion/2)])
    		rotate([90,0,0])
    		  cube([TabWidth,
    				(TabEngageLength + Protrusion),
    				(TabHeight + Protrusion)],center=true);
    
    	translate([-CaseOverallWidth,
    			  -(TabEngageHeight + LatchBarWidth - BatteryClearance),
    			  (TopThick - LatchBarDepth)])
    	  cube([2*CaseOverallWidth,(LatchBarWidth + LatchBarThick),(LatchBarDepth + Protrusion)]);
    
    	for (x=[-1,1])
    	  translate([(x*CaseOverallWidth/4),
    				-(TabEngageHeight + LatchBarWidth + Clear2_56/2 - BatteryClearance + Protrusion),
    				0]) {
    		translate([0,0,-Protrusion])
    		  rotate(45)						// align sides with slot
    			PolyCyl(Tap2_56,(TopThick + 2*Protrusion));
    		translate([0,0,(TopThick - LatchBarDepth)])
    		  rotate(60)						// align sides with slot
    			PolyCyl((Head2_56 + Protrusion),TopThick,6);		// extra extra clearance
    	  }
    
    	for (x=[-1,1])
    	  translate([x*(CaseOverallWidth/2 - PinOffsetWidth),-PinOffsetHeight,-Protrusion])
    		rotate(45)						// align hole side with plate side
    		  PolyCyl(PinDia,2*TopThick);
    
    	for (x=[-1,1])						// coincidentally line up with latch tabs
    	  translate([(x*TabOC/2),-(SplitOffset - 3.0),-Protrusion])
    		scale([1,1.7,1])
    		  PolyCyl(Cable1Dia,CableHoleLength,6);
      }
    
    }
    
    //-----
    // Speaker-Mic plug mounting plate
    
    module PlugPlate() {
    
    JackOC = 11.20;						// 14.25 OD - (3.58 + 2.58)/2
    
    JackScrewDia = 4.6;
    JackScrewOffsetX = 1.00;
    JackScrewOffsetY = 5.25;			//  mounting screw to edge of lower recess
    
    PlugBaseWidth = 9.25;				// lower section of plate
    PlugBaseLength = 22.0;
    PlugBaseRadius = 1.75;
    
    Plug3Offset = 5.25;					// edge of base recess to 3.5 mm jack
    
    Plug2BezelDia = 7.1;				// 2.5 mm plug
    Plug2BezelThick = 1.04;
    Plug2ScrewDia = 6.0;
    Plug3ScrewLength = 3.0;
    
    Plug3BezelDia = 8.13;				// 3.5 mm plug
    Plug3BezelThick = 1.6;
    Plug3ScrewDia = 7.95;
    Plug3ScrewLength = 4.0;
    
    PlugFillOffsetX = JackScrewOffsetX - 0.5;		// base recess CL to fill CL
    PlugFillOffsetY = -10.5;				//  ... to edge of fill plate
    PlugFillWidth = 11.0;
    PlugFillLength = 34.00;
    PlugFillRadius1 = 1.5;
    PlugFillRadius2 = 4.5;
    
    PlugFillOffsetYTotal = 0;
    
      BaseX = PlugBaseWidth/2 - PlugBaseRadius;
      BaseY = PlugBaseLength/2 - PlugBaseRadius;
    
      difference() {
    	union() {
    	  linear_extrude(height=PlugBaseThick,center=false,convexity=3)
    		hull() {
    		  translate([-BaseX,-BaseY,0])
    			circle(r=PlugBaseRadius,$fn=8);
    		  translate([-BaseX, BaseY,0])
    			circle(r=PlugBaseRadius,$fn=8);
    		  translate([ BaseX, BaseY,0])
    			circle(r=PlugBaseRadius,$fn=8);
    		  translate([ BaseX,-BaseY,0])
    			circle(r=PlugBaseRadius,$fn=8);
    		}
    
    	  translate([PlugFillOffsetX,
    				(PlugFillLength/2 - PlugBaseLength/2 + PlugFillOffsetY),
    				PlugBaseThick])
    		linear_extrude(height=PlugFillThick,center=false,convexity=5)
    		  hull() {
    			translate([0,-(PlugFillLength/2 - PlugFillRadius2),0])
    			  circle(r=PlugFillRadius2,$fn=10);
    			translate([-(PlugFillWidth/2 - PlugFillRadius1),-PlugBaseLength/2,0])
    			  circle(r=PlugFillRadius1,$fn=8);
    			translate([-(PlugFillWidth/2 - PlugFillRadius1),
    					  (PlugFillLength/2 - PlugFillRadius1),0])
    			  circle(r=PlugFillRadius1,$fn=8);
    			translate([(PlugFillWidth/2 - PlugFillRadius1),
    					  (PlugFillLength/2 - PlugFillRadius1),0])
    			  circle(r=PlugFillRadius1,$fn=8);
    			translate([(PlugFillWidth/2 - PlugFillRadius1),-PlugBaseLength/2,0])
    			  circle(r=PlugFillRadius1,$fn=8);
    		  }
    	}
    
    	translate([0,-JackOC/2,-Protrusion])
    	  rotate(360/16) {
    		PolyCyl(Plug3BezelDia,(Plug3BezelThick + Protrusion),8);
    		PolyCyl(Plug3ScrewDia,(PlugBaseThick + PlugFillThick + 2*Protrusion),8);
    	  }
    
    	translate([0,+JackOC/2,-Protrusion])
    	  rotate(360/16) {
    		PolyCyl(Plug2BezelDia,(Plug2BezelThick + Protrusion),8);
    		PolyCyl(Plug2ScrewDia,(PlugBaseThick + PlugFillThick + 2*Protrusion),8);
    	  }
    
    	translate([JackScrewOffsetX,-(PlugBaseLength/2 + JackScrewOffsetY),0])
    	  PolyCyl(JackScrewDia,(PlugBaseThick + PlugFillThick + Protrusion));
      }
    
    }
    
    //-------------------
    // Build things...
    
    ShowPegGrid();
    
    if (Layout == "TT3")
      TinyTrak3();
    
    if (Layout == "Audio")
      AudioInterface();
    
    if (Layout == "DSub")
      DSubMin9();
    
    if (Layout == "Shell")
      CaseShell(CaseOverallLength);
    
    if (Layout == "Top")
      TopPlate();
    
    if (Layout == "Base")
      Base();
    
    if (Layout == "RadioBase")
      RadioBase();
    
    if (Layout == "PlugPlate")
      PlugPlate();
    
    if (Layout == "Contact")
      rotate([180,0,0])
    	Contact();
    
    if (Layout == "Show" || Layout == "Fit") {
    
      translate([0,-ShellLength/2,0]) {
    
    	translate([0,(Layout == "Show")?-ShowGap:0,0])
    	  rotate([90,0,0])
    		color("SandyBrown") Base();
    
    	translate([0,0,0])
    	    color("Olive") render() CaseShell();
    
    	translate([-(CaseOverallWidth/2 + 10),50,CaseOverallHeight/2])
    	  rotate([0,-90,0])
    		color("Brown") PlugPlate();
    
    	translate([0,((Layout == "Show")?(ShellLength + ShowGap):ShellLength),0])
    	  rotate([-90,0,0])
    		color("Chocolate") TopPlate();
      }
    }
    
    if (Layout == "Build1") {
    
      translate([0,-CaseOverallHeight/2,ShellLength])
    	rotate([-90,0,0])
    		CaseShell();
    
    }
    
    if (Layout == "Build2") {
    
        translate([5 + CaseOverallHeight,0,0])
    	rotate([0,0,90])
    	  Base();
    
      translate([-(5 + CaseOverallHeight),0,0])
    	rotate(90)
    	  TopPlate();
    
    }
    
    if (Layout == "Build3") {
    
      translate([0,0,(PlugBaseThick + PlugFillThick)])
    	rotate([180,0,0])
    	  PlugPlate();
    
    }