Month: April 2017

The Perils of PDF
The Dodge Ram ProMaster cargo van we rented to haul our bikes to Glens Falls (and bring some furniture back) sat on their 2500 truck chassis, thus weaponizing an obvious phishing email waiting for me on our return:

Subject: About the Dodge ram 2500
Kindly review full details of your order.
Methner

The From and To addresses were identical, which is always a tipoff, as was the fact neither were any of my addresses. The email had an attached PDF, of course, although the context suggested handling it with the same nonchalance I’d use with any lump of high-level radioactive waste.

That brief text tripped my junk filters, but, somewhat to my surprise, all the scanners at VirusTotal passed Order 372.PDF without complaint (since then, one scanner woke up, smelled the scam, and tagged the file as “PDF/Phishing.A.Gen”).

Converting the PDF to plain text with pdftotext produced an empty file, so the PDF payload isn’t a script.

Passing the PDF through strings revealed a URL for a (probably compromised) server unrelated to the (obviously bogus) email address, wrapped with layout verbiage suggesting a clickable link:
```
<</Subtype/Link/Rect[ 205.25 467.11 369.91 499.51] /BS<</W 0>>/F 4/A<</Type/Action/S/URI/URI(http://bogus-domain-here.com/wp-settings/bloglist/hh/index.php) >>>>
```
Passing the PDF through pdftoppm produced this comforting image:

Bogus Order Form – Image

The “100% SECURE” padlock logo, with a green check for added confidence, is a nice touch.

At this point, if a product involves The Cloud, you can deal me out.
2017-04-30
Gas Pump UI: FAIL

During our most recent trip, I stopped at a new-to-me gas station, managed to figure out the pump’s UI enough to swipe my card and fill the tank, then utterly failed at the Print Receipt? prompt:

Gas Pump Keypad Abrasion

A quick hike to the adjacent pump suggested pressing the illegible key above Enter, but the UI timed out before I got back and the promised “moment” never ended. The attendant generated a receipt showing I’d paid for the gas and told me to jiggle the pump nozzle, which didn’t improve the situation. We eventually agreed he’d handle it later and I drove away, never to return, hoping that the next customer didn’t get a free fill on my ~~dime~~ ~~dollar~~ C-note.

Surely I’d know what to do, were I a regular customer …

2017-04-29

Badge Lanyard Reel Mount

A certain young engineer of my acquaintance now carries an ID badge and, so I hear, works in a PCB design & test venue. Seeing as how her favorite color is purple, this seemed appropriate:

Badge Lanyard Reel - front - overall — Badge Lanyard Reel – front – overall

The guts came from Circuit Breaker Labs in the form of a recycled PCB trapped in acrylic resin atop a plastic housing with a spring-loaded reel inside.

It arrived with a plastic bullet at the end of the lanyard:

Badge Lanyard Reel - plastic bullet link — Badge Lanyard Reel – plastic bullet link

Which I immediately replaced with brass, because Steampunk:

Badge Lanyard Reel - bullet cross-drill — Badge Lanyard Reel – bullet cross-drill

That made the plastic housing look weak, so, in a series of stepwise refinements, I conjured a much better case from the vasty digital deep:

Badge Lanyard Reel - iterations — Badge Lanyard Reel – iterations

All of the many, many critical dimensions lie inside the case, where they can’t be measured accurately, so each of those iterations could improve only one or two features. The absolutely wonderful thing about OpenSCAD is having it regenerate the whole model after loosening, say, the carabiner slot by two thread thicknesses; you can do that with a full-on relational CAD drawing, but CAD drawings always seems like a lot of unnecessary work if I must figure out the equations anyway.

The back sports my favorite Hilbert Curve infill with a nicely textured finish:

Badge Lanyard Reel - rear - oblique — Badge Lanyard Reel – rear – oblique

It’d surely look better in solid brass with Hilbert curve etching.

Black PETG doesn’t photograph well, but at least you can see the M2 brass inserts:

Badge Lanyard Reel - lower interior — Badge Lanyard Reel – lower interior

The first prototype showed the inserts needed far more traction than the usual reamed holes could provide, so I added internal epoxy grooves in each hole:

Badge Lanyard Reel Mount - show — Badge Lanyard Reel Mount – show

Recessing the screw heads into the top plate made them more decorative and smoother to the touch. Button-head screws would be even smoother, but IMO didn’t look quite as bold.

After seeing how well the grooves worked, I must conjure a module tabulating all the inserts on hand and automagically generating the grooves.

The yellow star holds up the roof of the reel recess in the build layout:

Badge Lanyard Reel Mount - build layout - bottom — Badge Lanyard Reel Mount – build layout – bottom

Slic3r produced the rest of the support material for the carabiner exit slot:

Badge Lanyard Reel Mount - bottom - Slic3r support — Badge Lanyard Reel Mount – bottom – Slic3r support

Those two support lumps on the right don’t actually support anything, but tweaking the support settings to disable them also killed the useful support on the left; come to find out Slic3r’s modifier meshes don’t let you disable support generation.

The top plate required support all the way around the inside of the bezel:

Badge Lanyard Reel Mount - top - Slic3r support — Badge Lanyard Reel Mount – top – Slic3r support

I carved the original plastic housing in half, roughly along its midline, and discarded the bottom section with the belt clip (it’s on the far left of the scrap pile). The top section, with PCB firmly affixed, holds the lanyard reel and anchors the retracting spring in a central slotted peg. No pictures of that, as it’s either a loose assembly of parts or a spring-loaded bomb and I am not taking it apart again.

The lanyard passes through an eyelet that pays it out to the rotating reel. I’d definitely do that differently, were I building it from scratch, because mounting the eyelet in exactly the proper position to prevent the lanyard from stacking up on the reel and jamming against the inside of the housing turned out to be absolutely critical and nearly impossible.

The top plate presses the original housing against the carabiner, with the cut-off section inside the carabiner’s circular embrace, which just barely worked: the PCB bezel is a millimeter smaller than the shoulder of the housing.

All in all, I think it came out really well for a 3D printed object made by a guy who usually builds brackets:

Badge Lanyard Reel - front - oblique — Badge Lanyard Reel – front – oblique

I hope she likes it …

The OpenSCAD source code as a GitHub Gist:

	// Badge Lanyard Reel Mount
	// Ed Nisley KE4ZNU April 2017
	// Reel center at origin, lanyard exit toward +X

	Layout = "Show";

	Support = true;

	//- Extrusion parameters must match reality!

	ThreadThick = 0.20;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

	Protrusion = 0.05; // make holes end cleanly

	inch = 25.4;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	//———————-
	// Dimensions

	ID = 0; // for round things
	OD = 1;
	LENGTH = 2;

	Carabiner = [30.7,35.3,3.5]; // metal carabiner around original reel
	Latch = [6.0,-15,8.0]; // wire spring latch: offset from OD + thickness
	LatchAngle = 60; // max deflection angle to center from -X direction

	LatchPoints = [[0,0],
	[Latch[1]/tan(LatchAngle),0],
	[Latch[1]/tan(LatchAngle),-Latch[1]]]; // polygon in as-cut orientation

	echo(str("Latch polygon: ",LatchPoints));

	Screw = [2.0,3.8 + 0*ThreadWidth,10.0]; // M2 screw: ID = clear, OD = head
	ScrewHeadLength = 2.0;
	ScrewSides = 8;
	ScrewRecess = 5*ThreadThick;

	MountSides = ScrewSides; // suitably gritty corners

	MountThick = Screw[LENGTH] / cos(180/MountSides) + ScrewRecess + 2.0;

	Insert = [Screw[ID],3.4,4.0]; // brass insert for screws

	BCD = Carabiner[OD] + 2.5*Insert[OD];

	BoltAngles = [20,110]; // ± angles to bolt holes

	Reel = [5.3,25.5 + 2ThreadWidth,6.0 + 2ThreadThick]; // lanyard cord reel
	ShimThick = 2*ThreadThick; // covers open side of reel for better sliding

	Bezel = [31.0,32.0,7.5]; // PCB holder + shell, LENGTH = post + shell
	BezelSides = 6*4;
	BezelBlock = [5.5,7.5,3.6] + [ThreadWidth,ThreadWidth,ThreadThick]; // block around lanyard eyelet

	Eyelet = [3.5,4.5,3.0];

	Bullet = [2.0,6.5,2.0]; // brass badge holder, LENGTH = recess into mount

	//———————-
	// 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);
	}

	//– Lanyard reel mockup

	module Reel() {

	cylinder(d=Reel[OD],h=Reel[LENGTH],center=true,$fn=6*4);

	}

	// Carabiner metal mockup
	// Some magic numbers lie in wait

	module Beener() {

	difference() {
	hull() {
	cylinder(d=Carabiner[OD],
	h=Carabiner[LENGTH] + 2*ThreadThick,
	center=true,$fn=BezelSides);
	translate([-Carabiner[OD]/2,0,0])
	cylinder(d=Carabiner[OD] – 2.0,
	h=Carabiner[LENGTH] + 2*ThreadThick,
	center=true,$fn=6*4);
	}
	cylinder(d=Carabiner[ID],
	h=2*Carabiner[LENGTH],
	center=true,$fn=BezelSides);
	translate([Carabiner[ID]/4,0,0])
	cube([Carabiner[ID],7.0,2*Carabiner[LENGTH]],center=true);
	}
	}

	// mockup of PCB holder atop remains of old mount with reel post
	// Z = 0 at midline of case

	module BezelMount() {

	rotate(180/BezelSides) {
	PolyCyl(Bezel[ID] + HoleWindage,MountThick,BezelSides); // PCB punches through mount
	PolyCyl(Bezel[OD] + HoleWindage,Bezel[LENGTH] – Reel[LENGTH]/2,BezelSides);
	}

	translate([Reel[OD]/2,0,BezelBlock[2]/2])
	scale([2,1,1])
	cube(BezelBlock,center=true);
	}

	// Main mount around holder & carabiner

	module Mount(Section="All") {

	render()
	difference() {
	hull() {
	for (a = BoltAngles) // spheres defining corners
	for (i=[-1,1])
	rotate(i*a)
	translate([BCD/2,0,0])
	sphere(d=MountThick,$fn=MountSides);
	cylinder(d=Carabiner[OD] + 4*ThreadWidth,
	h=MountThick,center=true); // capture carabiner ring
	}

	for (a = BoltAngles) // screw & insert holes, head recess
	for (i=[-1,1])
	rotate(i*a)
	translate([BCD/2,0,0])
	rotate(0i180/ScrewSides) {
	translate([0,0,-(Insert[LENGTH] + 2*ThreadThick)])
	PolyCyl(Insert[OD],
	Insert[LENGTH] + 2*ThreadThick + Protrusion,ScrewSides);
	for (k = [-2:2]) // epoxy retaining grooves
	translate([0,0,-(k3ThreadThick + Insert[LENGTH]/2)])
	PolyCyl(Insert[OD] + 1*ThreadWidth,
	2*ThreadThick,ScrewSides);
	PolyCyl(Screw[ID],Screw[LENGTH],ScrewSides);
	translate([0,0,MountThick/2 – ScrewRecess]) // recess screw heads
	PolyCyl(Screw[OD],Screw[LENGTH],ScrewSides);
	}

	translate([0,0,-1*ThreadThick]) // Minkowski Z extends only top surface!
	minkowski() { // space for metal carabiner
	Beener();
	// cube([ThreadWidth,ThreadWidth,2*ThreadThick]);
	cylinder(d=ThreadWidth,h=2*ThreadThick,$fn=6);
	}

	rotate([0,90,0]) rotate(180/6) // cord channel = brass tube clearance
	PolyCyl(Bullet[ID],Carabiner[ID],6);

	translate([Eyelet[LENGTH] + 2.0,0,0]) // eyelet, large end inward
	rotate([0,90,0]) rotate(180/6)
	PolyCyl(Eyelet[OD] + HoleWindage, Reel[OD]/2,6);

	if (false)
	translate([Reel[OD]/2 + Eyelet[LENGTH]/2,0,0]) // eyelet, small end outward
	rotate([0,90,0]) rotate(180/6)
	PolyCyl(Eyelet[ID],Eyelet[LENGTH],6);

	translate([(BCD/2 + MountThick/2)*cos(BoltAngles[0]) – Bullet[LENGTH],0,0]) // bullet recess
	rotate([0,90,0]) rotate(180/6)
	PolyCyl(Bullet[OD],Carabiner[ID],6);

	BezelMount(); // PCB holder clearance

	Reel(); // reel clearance

	translate([0,0,-(Reel[LENGTH] + ShimThick)/2]) // sliding plate on open side of reel
	cylinder(d=Reel[OD],h=ShimThick,center=true,$fn=6*4);

	translate([-Carabiner[OD]/2 + Latch[0],Latch[1],0])
	linear_extrude(height=Latch[2],center=true)
	polygon(LatchPoints);

	if (Section == "Upper") // display & build section cutting
	translate([0,0,-2*Carabiner[LENGTH]])
	cube(4*Carabiner,center=true);
	else if (Section == "Lower")
	translate([0,0,2*Carabiner[LENGTH]])
	cube(4*Carabiner,center=true);

	}

	if (Support) { // Completely ad-hoc support structures
	color("Yellow", Layout == "Show" ? 0.3 : 1.0) {
	if (false && Section == "Upper") {
	Spokes = BezelSides;
	Offset = 6*ThreadWidth;
	for (i = [2:Spokes – 2])
	rotate(i * 360/Spokes)
	translate([Offset,-ThreadWidth,0*(Carabiner[LENGTH]/2)/2])
	cube([Carabiner[OD]/2 – Offset – 0*ThreadWidth,
	2*ThreadWidth,
	Carabiner[LENGTH]/2],center=false);
	for (i = [0:Spokes – 1])
	rotate(i * 360/Spokes)
	translate([Offset,-ThreadWidth,0])
	cube([Bezel[OD]/2 – Offset,
	2*ThreadWidth,
	Bezel[LENGTH] – Reel[LENGTH]/2 – 2*ThreadThick],center=false);
	Bars = 7;
	render()
	difference() {
	union() {
	for (i = [-floor(Bars/2) : floor(Bars/2)])
	translate([-Carabiner[ID]/2,i*Carabiner[OD]/Bars,Carabiner[LENGTH]/4])
	cube([Carabiner[ID]/3,2*ThreadWidth,Carabiner[LENGTH]/2],center=true);
	translate([-Carabiner[ID]/2,0,ThreadThick/2])
	cube([Carabiner[ID]/3,Carabiner[ID],ThreadThick],center=true);
	}
	cylinder(d=Carabiner[ID] + 2*ThreadWidth,h=Carabiner[LENGTH]);
	}
	}
	if (Section == "Lower") {
	translate([0,0,-(Reel[LENGTH]/4 + ShimThick/2 – ThreadThick/2)])
	for (i = [0:8])
	rotate(i * 360/8)
	cube([Reel[OD] – 2*ThreadWidth,
	2*ThreadWidth,
	Reel[LENGTH]/2 + ShimThick – ThreadThick],center=true);
	if (false) {
	Bars = 7;
	render()
	difference() {
	union() {
	for (i = [-floor(Bars/2) : floor(Bars/2)])
	translate([-Carabiner[ID]/2,i*Carabiner[OD]/Bars,-Carabiner[LENGTH]/4])
	cube([Carabiner[ID]/3,2*ThreadWidth,Carabiner[LENGTH]/2],center=true);
	translate([-Carabiner[ID]/2,0,-ThreadThick/2])
	cube([Carabiner[ID]/3,Carabiner[ID],ThreadThick],center=true);
	}
	translate([0,0,-Carabiner[LENGTH]])
	cylinder(d=Carabiner[ID] + 0*ThreadWidth,h=Carabiner[LENGTH]);
	}
	}
	}
	}
	}

	}



	//———————-
	// Build it

	if (Layout == "Beener")
	Beener();

	if (Layout == "Mount")
	Mount();

	if (Layout == "Reel")
	Reel();

	if (Layout == "BezelMount")
	BezelMount();

	Gap = 25;
	if (Layout == "Show") {
	translate([0,0,Gap/2])
	Mount("Upper");
	translate([0,0,-Gap/2])
	Mount("Lower");
	color("Green",0.3)
	Beener();
	color("Brown",0.3)
	Reel();
	color("Red",0.3)
	translate([0,0,-(Reel[LENGTH] + ShimThick)/2])
	cylinder(d=Reel[OD],h=ShimThick,center=true,$fn=6*4);
	}

	if (Layout == "Build") {
	translate([(BCD + MountThick)/2,0,0])
	rotate(180)
	Mount("Upper");
	rotate([180,0,0])
	translate([-(BCD + MountThick)/2,0,0])
	Mount("Lower");
	}

	if (Layout == "BuildUpper")
	Mount("Upper");

	if (Layout == "BuildLower")
	rotate([180,0,0])
	Mount("Lower");

view raw Badge Lanyard Reel Mount.scad hosted with ❤ by GitHub

2017-04-28

Eneloop AAA Cells: First Charge

With an AAA-to-AA adapter in hand, the Eneloop AAA cells looked like this:

Eneloop AAA – as received – Ah scale – 2017-04-20

The glitch comes from a not-quite-seated cell, showing that a poor connection matters.

The package touts “up to 800 mA·h, 750 mA·h min”, with asterisks and superscripts leading to “Based on IEC 61951-2(7.3.2)“, access to which requires coughing up 281 bucks. So it goes.

A full charge made them happier:

Eneloop AAA – first charge – Ah scale – 2017-04-22

The as-delivered 530 mA·h capacity represents 73% of the 725 mA·h after the first charge, so I suppose they’re more-or-less within the “Maintains up to 70% charge after 10 years of storage” claim. The 16-10 date code suggests they’re hot off the factory charger, so they must ship with somewhat less than a full charge.

Comparing the capacity in W·h makes more sense, because most devices (other than the Planet Bike blinky light these will go into, of course) use a boost converter to get a fixed voltage from the declining terminal voltage.

They arrived bearing just over 600 mW·h:

Eneloop AAA – as received – Wh scale – 2017-04-20

After charging, that went a bit over 850 mW·h :

Eneloop AAA – first charge – Wh scale – 2017-04-22

Call it 71% of full capacity on arrival. Close enough.

The Planet Bike blinky will be somewhat dimmer with two NiMH cells delivering 2.3-ish V, compared with the initial 3-ish V from a pair of alkaline cells. I generally burn the alkalines down to 1.1 V apiece, so perhaps they’ll be Good Enough.

Now, if I were gutsy, I’d install a rechargeable lithium AAA cell, with a dummy pass-through adapter in the other cell socket, and run the blinky at 3.7 V. At least for a few moments, anyhow …

2017-04-27

Tour Easy Front Fender Clip

We rode the Feeder Canal trail during a recent bike vacation in exotic Glens Falls NY:

Feeder Canal Park Trail - Branches — Feeder Canal Park Trail – Branches

The numerous downed branches along the trail and countless twigs on the trail came from a brush-clearing operation:

Feeder Canal Park Trail - Brush Clearing — Feeder Canal Park Trail – Brush Clearing

As luck would have it, a twig snagged between my front tire and fender, snapping the clips holding the fender in place:

Should it not be obvious, each ferrule formerly had two parallel jaws (on the left) gripping the fender, with the tiny screw digging into the fender. I affixed the fender to the broken clips with copious amounts of duct tape and we continued the mission.

It should be obvious why those ferrules are not suitable for 3D printing.

However, with the recent rear fender clip serving as inspiration, this didn’t take long:

Tour Easy - Front Fender Clip - Slic3r — Tour Easy – Front Fender Clip – Slic3r

The front fender fits a 20 inch wheel and is somewhat wider and flatter than the rear fender (I think they bent the same plastic strip around a smaller mandrel), so I did a quick copy-and-paste hack job on the OpenSCAD source code, rather than trying to parameterize the daylights out of the previous model.

The posts around the wire stays are 6 diameters deep and reamed to fit; the stays won’t be flopping around even without fiddly mechanical hardware retaining them. The holes extend about halfway into those posts to mimic the dimensions of the original ferrules.

All of us can predict where the next break will occur, right? That’s OK: I want this to break, instead of wrecking the fender, so the only question is how much abuse those simple joints can withstand. The printing orientation wraps the perimeter threads from the posts around the clip, making it about a strong as it can be.

The ferrules should splay outward by a few degrees to match the angle from the fender to the fork eyelets, but that’s in the nature of fine tuning.

The arch accommodates a strip of double-sided foam tape holding the clip in place along the fender curve, with those cute little hooks capturing the fender to keep the tape in compression:

Tour Easy Front Fender Clip - installed — Tour Easy Front Fender Clip – installed

I really must get some black foam tape …

The picture shows the fender sitting well away from the tire, due to the upper fender mount bending in response to the splash flap snagging on curbs and random debris; the wire stays didn’t seat completely into the posts.

The extender I made during the cracked fork episode remained perfectly straight, though:

Tour Easy - new fork - fender extender — Tour Easy – new fork – fender extender

So I re-bent the upper fender mount (not the extender!) to its original angle, thereby moving the bottom of the fender much closer to the tire. Now the stays seat fully, the clip holds the fender firmly in place with no rattles, and it’s all good.

The OpenSCAD source code as a GitHub Gist:

	// Tour Easy front fender clip
	// Ed Nisley KE4ZNU April 2017

	Layout = "Clip"; // Build Profile Ferrule Clip

	//- Extrusion parameters must match reality!

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

	Protrusion = 0.1; // make holes end cleanly

	inch = 25.4;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	//———————-
	// Dimensions

	// special case: fender is exactly half a circle!

	FenderC = 51.0; // fender outside width = chord
	FenderM = 21.0; // height of chord

	FenderR = (pow(FenderM,2) + pow(FenderC,2)/4) / (2 * FenderM); // radius
	echo(str("Fender radius: ", FenderR));
	FenderD = 2*FenderR;

	FenderA = 2 * asin(FenderC / (2*FenderR));
	echo(str(" … arc: ",FenderA," deg"));

	FenderThick = 2.5; // fender thickness, assume dia of edge

	ClipHeight = 15.0; // top to bottom, ignoring rakish tilt
	ClipThick = 3.0; // thickness of clip around fender
	ClipD = FenderD; // ID of clip against
	ClipSides = 4 * 8; // polygon sides around clip circle

	BendReliefD = 2.5; // bend arch diameter
	BendReliefA = 2/3 * FenderA/2; // … angle from dead ahead
	BendReliefCut = 1.0; // factor to thin outside of bend

	ID = 0;
	OD = 1;
	LENGTH = 2;

	StayDia = 3.3; // fender stay rod diameter
	StayOffset = 23.0; // stay-to-fender distance
	StayAngle = -5; // angle from stay to fender

	FerruleSides = 2*4;
	Ferrule = [StayDia,3FenderThick/cos(180/FerruleSides),6StayDia + StayOffset]; // ID = stay rod OD

	//———————-
	// 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);
	}

	//———————-
	// Clip profile around fender
	// Centered on fender arc

	module Profile(HeightScale = 1) {

	linear_extrude(height=HeightScale*ClipHeight,convexity=5) {
	difference() {
	offset(r=ClipThick) // outside of clip
	union() {
	circle(d=ClipD,$fn=ClipSides);
	for (i=[-1,1])
	rotate(i*BendReliefA) {
	translate([ClipD/2 + BendReliefD/2,0,0])
	circle(d=BendReliefD,$fn=6);
	}
	}
	union() { // inside of clip
	circle(d=ClipD,$fn=ClipSides);
	for (i=[-1,1])
	rotate(i*BendReliefA) {
	translate([ClipD/2 + BendReliefCut*BendReliefD/2,0,0])
	circle(d=BendReliefD/cos(180/6),$fn=6);
	translate([ClipD/2,0,0])
	square([BendReliefCut*BendReliefD,BendReliefD],center=true);
	}
	}
	translate([(FenderR – FenderM – FenderD/2),0]) // trim ends
	square([FenderD,2*FenderD],center=true);
	}

	for (a=[-1,1]) // hooks around fender
	rotate(a*(FenderA/2))
	translate([FenderR – FenderThick/2,0]) {
	difference() {
	rotate(1*180/12)
	circle(d=FenderThick + 2*ClipThick,$fn=12);
	rotate(1*180/8)
	circle(d=FenderThick,$fn=8);
	rotate(a * -90)
	translate([0,-2*FenderThick,0])
	square(4*FenderThick,center=false);
	}
	}
	}
	}


	//———————-
	// Ferrule body

	module FerruleBody() {

	translate([0,0,Ferrule[OD]/2 * cos(180/FerruleSides)])
	rotate([0,-90,0]) rotate(180/FerruleSides)
	difference() {
	cylinder(d=Ferrule[OD],h=Ferrule[LENGTH],$fn=FerruleSides,center=false);
	translate([0,0,StayOffset + Protrusion])
	PolyCyl(Ferrule[ID],Ferrule[LENGTH] – StayOffset + Protrusion,FerruleSides);
	}

	}

	//———————-
	// Generate entire clip at mounting angle

	module FenderClip() {

	union() {
	translate([FenderR,0,0])
	difference() { // angle and trim clip
	rotate([0,StayAngle,0])
	translate([-(FenderR + ClipThick),0,0])
	Profile(2); // scale upward for trimming
	translate([0,0,-ClipHeight]) // trim bottom
	cube(2*[FenderD,FenderD,ClipHeight],center=true);
	translate([0,0,ClipHeight*cos(StayAngle)+ClipHeight]) // trim top
	cube(2*[FenderD,FenderD,ClipHeight],center=true);
	}
	for (j = [-1,1])
	translate([Ferrule[OD]sin(StayAngle),j(FenderR – FenderThick + FenderThick/2),0])
	FerruleBody();
	}
	}

	//———————-
	// Build it


	if (Layout == "Profile") {
	Profile();
	}

	if (Layout == "Ferrule") {
	FerruleBody();
	}

	if (Layout == "Clip") {
	FenderClip();
	}

	if (Layout == "Build") {
	FenderClip();
	}

view raw Front Fender Clip.scad hosted with ❤ by GitHub

2017-04-26

Microscope 60 LED Ring Light Adapter

The Barbie-themed microscope light I built from an angel eye LED ring worked fine for the last six years (!), but a much brighter ring with 60 aimed 5 mm LEDs for $17 delivered from a US seller caught my eye:

Microscope 60 LED ring light - in use — Microscope 60 LED ring light – in use

Although this ring looks much more professional, it didn’t quite fit the microscope, being designed for a round snout rather than a squarish one. This snout has a 47-ish mm threaded ring intended for filters & suchlike, so I built an adapter between that and the 60 mm ID of the LED ring:

Microscope 60 LED Ring Light Adapter - top - Slic3r — Microscope 60 LED Ring Light Adapter – top – Slic3r

The ring came with three long knurled screws which I replaced with much tidier M3 socket-head screws going into those holes:

Microscope 60 LED ring light - assembled - top — Microscope 60 LED ring light – assembled – top

The part going into the snout threads is deliberately (honest!) a bit small, so I could wrap it with soft tape for a good friction fit. The Barbie Ring didn’t weigh anything and I wound up using squares of double-sticky foam tape; it could come to that for this ring, too.

The adapter features a taper on the bottom for no particularly good reason, as the field-of-view tapers inward, not outward:

Microscope 60 LED Ring Light Adapter - bottom - Slicer — Microscope 60 LED Ring Light Adapter – bottom – Slicer

Seen from the bug’s POV, it’s a rather impressive spectacle:

Microscope 60 LED ring light - assembled - bottom — Microscope 60 LED ring light – assembled – bottom

The control box sports a power switch and a brightness knob. Come to find out the ring is actually too bright at full throttle; a nice problem to have.

That was easy!

The OpenSCAD source code as a GitHub Gist:

	// LED Ring Light Mount – 60 mm ID ring
	// Ed Nisley KE4ZNU April 2017

	//- Extrusion parameters must match reality!

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

	Protrusion = 0.1; // make holes end cleanly

	inch = 25.4;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	//———————-
	// Dimensions

	ID = 0;
	OD = 1;
	LENGTH = 2;

	ScopeThread = [43.0,46.5,4.0]; // scope snout thread, ID = minimum invisible

	LEDRing = [ScopeThread[ID],60.0,8.0];
	LEDScrewOffset = 4.0;
	LEDScrewOD = 3.0;
	LEDScrews = 3;

	OAH = ScopeThread[LENGTH] + LEDRing[LENGTH];

	NumSides = 34LEDScrews; // get symmetry for screws

	//———————-
	// 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);
	}

	//———————-
	// Build it

	difference() {
	rotate(180/NumSides)
	union() {
	cylinder(d=ScopeThread[OD],h=OAH,$fn=NumSides);
	cylinder(d=LEDRing[OD],h=LEDRing[LENGTH],$fn=NumSides);
	}

	translate([0,0,-Protrusion])
	rotate(180/NumSides)
	cylinder(d=ScopeThread[ID],h=OAH + 2*Protrusion,$fn=NumSides);

	translate([0,0,-Protrusion])
	rotate(180/NumSides)
	cylinder(d1=LEDRing[OD] – 26ThreadWidth,
	d2=ScopeThread[ID],
	h=LEDRing[LENGTH] + Protrusion,$fn=NumSides);

	for (i=[0:LEDScrews-1])
	rotate(i*360/LEDScrews)
	translate([LEDRing[OD]/2 – LEDScrewOD,0,LEDRing[LENGTH] – LEDScrewOffset])
	rotate([0,90,0]) rotate(180/6)
	cylinder(d=LEDScrewOD,h=LEDScrewOD + Protrusion,$fn=6);
	}

view raw LED Ring Light Mount – 60 mm.scad hosted with ❤ by GitHub

2017-04-25

Cylindrical Cell Adapters

An octet of Eneloop AAA cells arrived, I wanted to measure their as-delivered charge (the package says “Factory Charged With SOLAR ENERGY”, so you know it’s good), and discovered I’d given away my AAA cell holders. You can actually get inter-series adapters on eBay, but what’s the fun in that? Plus, I didn’t want to delay gratification for a month; you know how it is.

Soooo:

AAA to AA Adapter - top - Slic3r — AAA to AA Adapter – top – Slic3r

It’s basically an AA-size sleeve that fits over the AAA cell, with a lathe-turned brass post conducting juice from the + terminal of the inner cell outward:

AAA to AA Adapter - parts — AAA to AA Adapter – parts

Not much to look at when it’s assembled:

AAA to AA Adapter - assembled — AAA to AA Adapter – assembled

The AAA cell fits deliberately loose, because this goes into a metal clip holding everything firmly in place for the battery tester:

AAA to AA Adapter - in use — AAA to AA Adapter – in use

The source code tabulates the sizes of several cylindrical cells, exactly zero other pairs of which have been tested; I expect most won’t work correctly. In particular, the table entries should include the contact button OD and thickness for each cell, so that I can turn out the proper terminal for each pair of cells. If I ever need a different adapter, I’ll beat some cooperation out of that, too.

Discovered I needed an adapter after breakfast, started testing cells after lunch. Life is good!

The OpenSCAD source code as a GitHub Gist:

	// Cylindrical cell adapters
	// Ed Nisley KE4ZNU April 2017

	//- Extrusion parameters must match reality!

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

	Protrusion = 0.1; // make holes end cleanly

	inch = 25.4;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	//———————-
	// Dimensions

	OutCell = "AA"; // cell sizes
	InCell = "AAA";

	BottomClear = 3*ThreadThick; // shorten outer shell to allow base protrusion
	Terminal = [3.0,4.0,2.0]; // terminal: OD = nub dia, length = nub thickness

	NAME = 0;
	ID = 0; // for non-cell cylinders
	OD = 1;
	LENGTH = 2;

	Cells = [
	["AAAA",8.3,42.5],
	["AAA",10.5,44.5],
	["AA",14.5,50.5],
	["C",26.2,50],
	["D",34.2,61.5],
	["A23",10.3,28.5],
	["CR123",17.0,34.5],
	["18650",18.6,65.2]
	];

	Outer = search([OutCell],Cells,1,0)[0];
	Inner = search([InCell],Cells,1,0)[0];

	echo(str("Outer cell: ",Cells[Outer][NAME]));
	echo(str("Inner cell: ",Cells[Inner][NAME]));

	echo(str("Wall: ",Cells[Outer][OD] – (Cells[Inner][OD]/cos(180/NumSides) + 2*ThreadWidth)));

	Delta = Cells[Outer][LENGTH] – Cells[Inner][LENGTH];

	echo(str("Terminal OAL: ",Delta));
	echo(str(" … head: ",Terminal[LENGTH]));
	echo(str(" … shaft: ",Delta – Terminal[LENGTH]));

	NumSides = 3*4;

	//———————-
	// 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);

	}

	//———————-
	// Construct adapter

	module Adapter() {

	difference() {
	cylinder(d=Cells[Outer][OD],
	h=Cells[Outer][LENGTH] – BottomClear – Terminal[LENGTH],
	$fn=NumSides);

	translate([0,0,Delta – Terminal[LENGTH]])
	PolyCyl(Cells[Inner][OD] + 2*ThreadWidth,
	Cells[Inner][LENGTH] + Protrusion,
	NumSides);

	translate([0,0,-Protrusion])
	PolyCyl(Terminal[ID],
	2*Cells[Outer][LENGTH],
	6);
	}
	}

	//———————-
	// Build it

	Adapter();

view raw Cylindrical Cell Adapters.scad hosted with ❤ by GitHub

The original doodle:

AAA to AA Adapter - sketch — AAA to AA Adapter – sketch

2017-04-24

Month: April 2017

The Perils of PDF

Gas Pump UI: FAIL

Badge Lanyard Reel Mount

Eneloop AAA Cells: First Charge

Tour Easy Front Fender Clip

Microscope 60 LED Ring Light Adapter

Cylindrical Cell Adapters