The New Hotness

The bandsaw now sports a chunky mount for its gooseneck light:

USB Gooseneck Mount - on bandsaw — USB Gooseneck Mount – on bandsaw

The gooseneck ends in a USB Type-A plug, so an ordinary USB extension cable can connect it to the hacked hub supplying 9 VDC:

USB Gooseneck Mount - interior — USB Gooseneck Mount – interior

The plastic came from a slightly earlier version of the solid model, with one foam pad under the gooseneck’s USB plug to soak up the clearance. The four smaller holes, with M3 brass inserts visible in the bottom half (on the right), clamp the gooseneck connector in place against the foam; you could push it out if you were really determined, but you’d have to be really determined.

If I ever build another one, it’ll sandwich the plug between opposing pads:

USB Gooseneck Connector Mount - Slic3r preview — USB Gooseneck Connector Mount – Slic3r preview

The lettering on the block stands out much better in the solid model:

USB Gooseneck Connector Mount - solid model - overview — USB Gooseneck Connector Mount – solid model – overview

Obviously, I need help with the stylin’ thing. This looks better, but with terrible overhangs for printing in the obvious no-support orientation:

USB Gooseneck Connector Mount - solid model - rounded top — USB Gooseneck Connector Mount – solid model – rounded top

Anyhow, the USB extension cable (on the left) has plenty of clearance and pulls straight out of the housing, so I can remove the bandsaw cover without unwiring:

USB Gooseneck Mount - assembled — USB Gooseneck Mount – assembled

The LED ticks along at 40 °C in a 14 °C basement, suggesting a thermal coefficient around 14 °C/W. Even in the summer months, with the basement around 25 °C, there’s no risk of PETG softening at 50 °C.

I’ll epoxy a similar 1.8 W COB LED onto the curve of the bandsaw frame where it can shine on the left and rear part of the table; it doesn’t even need a case.

The OpenSCAD source code as a GitHub Gist:

	// Gooseneck lamp for MicroMark bandsaw
	// Ed Nisley KE4ZNU
	// February 2017

	Layout = "Mount"; // Mount Show Build

	Gap = 5; // distance between halves for Show

	//- 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

	Tap10_32 = 0.159 * inch;
	Clear10_32 = 0.190 * inch;
	Head10_32 = 0.373 * inch;
	Head10_32Thick = 0.110 * inch;
	Nut10_32Dia = 0.433 * inch;
	Nut10_32Thick = 0.130 * inch;
	Washer10_32OD = 0.381 * inch;
	Washer10_32ID = 0.204 * inch;

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

	Insert = [3.0,4.9,2*ThreadThick + IntegerMultiple(4.2,ThreadThick)]; // M3 short brass insert

	CornerRadius = 5.0; // rounded mount block corners for pretty
	CornerSides = 4*4;

	RoundedTop = true; // true for fancy smooth top edges

	USBPlug = [39.0,16.0,8.3]; // plug, X from base of plug
	USBSocket = [28.0,20.0,11.5]; // USB extension, X from tip of socket

	USBMating = [-12.0,0,0]; // offset of plug base relative to block center

	Foam = [35.0,10.0,2.0 – 1.0]; // foam pad to secure USB plug (Z = thickness – compression)

	GooseneckOD = 5.0; // flexy gooseneck diameter

	MountScrewOC = 35.0; // make simple screw hole spacing for bandsaw case

	MountBlock = [10*round((USBPlug[0] + USBSocket[0] + 5.0)/10),
	10*round((MountScrewOC + Washer10_32OD + 5.0)/10),
	// 26ThreadThick + IntegerMultiple(max(USBPlug[2],USBSocket[2]),ThreadThick)];
	16.0]; // thickness = 16 mm M3x0.5 button head screw

	echo(str("Block size: ",MountBlock));

	LegendDepth = 2*ThreadThick; // lettering depth

	//———————-
	// 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);
	}

	//– Mount

	module Mount() {

	difference() {
	hull()
	if (RoundedTop) {
	for (i=[-1,1], j=[-1,1])
	translate([i(MountBlock[0]/2 – CornerRadius),j(MountBlock[1]/2 – CornerRadius),0]) {
	translate([0,0,-MountBlock[2]/2])
	rotate(180/CornerSides)
	cylinder(r=CornerRadius,h=MountBlock[2]/2,$fn=CornerSides,center=false);
	translate([0,0,MountBlock[2]/2 – CornerRadius])
	rotate(180/CornerSides)
	sphere(r=CornerRadius,$fn=CornerSides,center=true);
	}
	}
	else {
	for (i=[-1,1], j=[-1,1])
	translate([i(MountBlock[0]/2 – CornerRadius),j(MountBlock[1]/2 – CornerRadius),0])
	rotate(180/CornerSides)
	cylinder(r=CornerRadius,h=MountBlock[2],$fn=CornerSides,center=true);
	}
	for (j=[-1,1]) // screws into bandsaw case
	translate([0,j*MountScrewOC/2,-(MountBlock[2]/2 + Protrusion)])
	rotate(180/8)
	PolyCyl(Clear10_32,(MountBlock[2] + 2*Protrusion),8);
	for (i=[-1,1], j=[-1,1]) { // clamp screws
	translate([iMountBlock[0]/4,jMountScrewOC/2,-MountBlock[2]])
	PolyCyl(Insert[ID],2*MountBlock[2],6); // clearance
	translate([iMountBlock[0]/4,jMountScrewOC/2,-(MountBlock[2]/2 + Protrusion)])
	PolyCyl(Insert[OD],Insert[LENGTH] + Protrusion,6); // inserts
	}
	rotate([0,90,0]) // gooseneck flexy cable
	rotate(180/6)
	PolyCyl(GooseneckOD,MountBlock[0],6);

	translate([USBPlug[0]/2,0,0] + USBMating – [Protrusion/2,0,0]) // USB plug outline
	cube(USBPlug + [Protrusion,0,0],center=true);
	translate([-USBSocket[0]/2,0,0] + USBMating) // USB socket outline
	cube(USBSocket,center=true);

	translate([(Foam[0]/2 + 5*ThreadWidth),0,-(Foam[2]/2 + USBPlug[2]/2)] + USBMating – [Protrusion,0,-Protrusion]/2) // foam padding recess
	cube(Foam + [Protrusion,0,Protrusion],center=true); // foam packing
	translate([(Foam[0]/2 + 5*ThreadWidth),0, (Foam[2]/2 + USBPlug[2]/2)] + USBMating – [Protrusion,0, Protrusion]/2) // foam padding recess
	cube(Foam + [Protrusion,0,Protrusion],center=true);

	render(convexity=5)
	translate([0,0,MountBlock[2]/2 – LegendDepth])
	linear_extrude(height=LegendDepth + Protrusion) {
	translate([0,5,0])
	text(text="KE4ZNU",size=8,spacing=1.10,font="Bitstream Vera Sans:style=Bold",valign="center",halign="center");
	translate([0,-5,0])
	text(text="4 Feb 2017",size=6,spacing=1.05,font="Bitstream Vera Sans:style=Bold",valign="center",halign="center");
	}
	}
	}

	//———————-
	// Build it

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

	if (Layout == "Show") {
	translate([0,0,-Gap/2])
	difference() {
	Mount();
	translate([0,0,MountBlock[2]])
	cube(2*MountBlock,center=true);
	}
	translate([0,0,Gap/2])
	difference() {
	Mount();
	translate([0,0,-MountBlock[2]])
	cube(2*MountBlock,center=true);
	}
	}

	if (Layout == "Build") {
	translate([0,0.6*MountBlock[1],MountBlock[2]/2])
	difference() {
	Mount();
	translate([0,0,MountBlock[2]])
	cube(2*MountBlock,center=true);
	}
	translate([0,-0.6*MountBlock[1],MountBlock[2]/2])
	rotate([180,0,0])
	difference() {
	Mount();
	translate([0,0,-MountBlock[2]])
	cube(2*MountBlock,center=true);
	}
	}

view raw USB Gooseneck Connector Mount.scad hosted with ❤ by GitHub

The New Hotness

Bandsaw Worklight: USB Gooseneck Mount