The Smell of Molten Projects in the Morning

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

Day: July 9, 2012

  • Wouxun KG-UV3D GPS+Voice Interface: Improved Case

    This case has a few refinements beyond that one, but it’s recognizably a descendant. The main changes:

    • The HT cable port on the side has a nice polygonal roof to reduce overhang
    • The serial connector sits in a recess to allow a thicker top plate
    • Smaller opening for the LEDs; I’ll get a window in this one, fer shure, yeah
    • 4-40 screws hold the base plate on; setscrews may work and look better

    Looks like I’ll be using blue filament for this version, having just discovered the last of the weird colors in the bottom of the 5 gallon bucket serving as a storage bin.

    A view from the top:

    Solid Model - Oblique Exploded Top
    Solid Model – Oblique Exploded Top

    And from the base:

    Solid Model - Oblique Exploded Base
    Solid Model – Oblique Exploded Base

    The OpenSCAD source code:

    // Wouxun KB-UV3D Battery Pack Case
    // Ed Nisley KE4ZNU July 2012
    
    include </home/ed/Thing-O-Matic/lib/MCAD/units.scad>
    include </home/ed/Thing-O-Matic/Useful Sizes.scad>
    
    // Layout options
    
    Layout = "Show";
    					// 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 = 10;		// 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
    
    ContactDia = 6.0;				// use rounded contact for simplicity
    ContactRecess = IntegerMultiple(0.75,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 = IntegerMultiple(Head4_40,ThreadWidth);
    ContactStudHeadThick = Head4_40Thick;
    
    PlateWidthMin = 53.0;
    PlateWidthMax = 54.5;
    PlateThick = IntegerMultiple(ContactRecess + ContactStudHeadThick,ThreadThick);
    PlateAngle = atan(PlateThick/(PlateWidthMax/2 - PlateWidthMin/2));
    
    echo("Battery plate thick: ",PlateThick);
    
    // 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 = 13.5;				// 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 = [26.0,5.0,6];			// 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 = 3.5;
    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));
    		  }
    
    		  for (x=[-1,1])						// setscrews to secure base plate
    			translate([x*(CaseOverallWidth/2 - 3*Tap4_40),
    					  TT3Offset,-Protrusion])
    			  rotate(360/(5*4))
    				PolyCyl(Tap4_40,2*TopThick);
    
    		  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/4)])
    			rotate([0,90,0])
    			  cube([(HTCableDia/2 + Protrusion),HTCableDia,CaseOverallWidth],center=true);
    		  translate([0,HTCableOffset,(Length - HTCableDia/2)])
    			rotate([0,90,0])
    			  cylinder(r=(1/cos(30))*HTCableDia/2,h=CaseOverallWidth,$fn=6);
    		}
    	  }
    
    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])						// main case shape
    	  CaseShell(BaseTotalThick,false);
    
    	translate([0,0,BaseThick])				// radio base interface
    	  RadioBase();
    
    	translate([0,0,BaseThick])				// tooth bevel
    	  rotate([(-90 + BaseToothAngle),0,0])
    		translate([0,-0.5,0])
    		  cube([(BaseToothSection + 2*Protrusion),1.0,10],center=true);
    
    	translate([-BaseWidthOuter,				// surface slope
    			  -(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);
    		}
    
    	for (x=[-1,1])							// alignment pin holes
    	  translate([x*(CaseOverallWidth/2 - PinOffsetWidth),PinOffsetHeight,-Protrusion])
    		rotate(45)							// align hole side with plate side
    		  PolyCyl(PinDia,2*TopThick);
    
    	for (x=[-1,1])							// mounting setscews
    	  translate([x*(CaseOverallWidth/2 - 3*Tap4_40),
    				TT3Offset,-Protrusion])
    		rotate(-360/(-5*4))
    		  PolyCyl(Tap4_40,2*TopThick);
    
    	translate([(-SwitchBody[0]/2),TT3Offset,-SwitchBody[2]/2])	// mode switch
    	  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("LightGreen") render() CaseShell();
    
    	translate([-(CaseOverallWidth/2 + 10),50,CaseOverallHeight/2])
    	  rotate([0,-90,0])
    		color("Gold") PlugPlate();
    
    	translate([0,((Layout == "Show")?(ShellLength + ShowGap):ShellLength),0])
    	  rotate([-90,0,0])
    		color("BurlyWood") TopPlate();
    }
    }
    
    if (Layout == "Build1") {
    
    translate([5 + CaseOverallHeight,0,0])
    	rotate([0,0,90])
    	  Base();
    
    translate([-(5 + CaseOverallHeight),0,0])
    	rotate(90)
    	  TopPlate();
    
    }
    
    if (Layout == "Build2") {
    
    translate([0,-CaseOverallHeight/2,ShellLength])
    	rotate([-90,0,0])
    		CaseShell();
    
    }
    
    if (Layout == "Build3") {
    
    translate([0,0,(PlugBaseThick + PlugFillThick)])
    	rotate([180,0,0])
    	  PlugPlate();
    
    }