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Archive for April 13th, 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();

}
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