Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.
Based on those measurements that suggest spacing the plugs at 11.5 mm on center, I tweaked that parameter in the source code there and printed another one, just like the other one. Actually, I printed four of the fool things this time:
Wouxun plug plates – 11.5 mm fixture
With the plugs in the gluing fixture and the fixture in the vise, a ring of epoxy around the threaded sides holds them in place:
Wouxun plug plate – wired
A trial fit in the Wouxun KG-UV3D shows that the jacks prefer the 11.2 mm spacing I measured on the Wouxun headset, but they’ll accept plugs on 11.5 mm centers. I don’t know if that’s a real specification difference, a manufacturing tolerance, or what.
FWIW, I’ve been using snippets of that cable forever, because it’s perfect for this application: two unshielded conductors and three more inside a braid, supple as a snake. It’s surplus, of course, with a gorgeous push-lock plug (and the jack!) on one end that must have cost a fortune… and which I’ll never to use for anything. Got two of them, just in case.
Mushing an epoxy putty turd on the top anchors everything in place and protects the wires:
Wouxun plug plate – epoxy cap
In point of fact, the cable insulation isn’t anchored inside the blob and a minor tug could pull it loose. There will be a bit of slack at the case to allow for unlatching it from the radio, but the lashup will spend its entire life inside a snug pouch, so it shouldn’t come to any harm. We shall see.
Try as I might, I cannot uncover a definitive answer to this simple question: What’s the center-to-center spacing of the mic and earphone jacks on the side of Kenwood and Wouxun HTs?
The usual searches produce answers like 11 and 12 mm, both of which are obviously wrong, as can be determined eyeballometrically just by holding a scale against the plugs.
Based on measurements I made on a Wouxun headset, the yellow plug mounting plate put the plugs on 11.2 mm centers and they fit into the KG-UV3D radio; it’s been working fine ever since.
However, having just measured a speaker/mic and a headset, both from Kenwood, I come up with 11.5 mm. Frankly, I trust the Kenwood hardware a bit more: the plugs seem more rugged and the overall production values are higher.
The calculation is simple: measure the pin diameters, then subtract half their sum from the outside distance across the pins. Cross-check by adding half the sum to the inside distance between the pins, which should give the same answer. It helps if the pins are actually round.
The jacks in the Kenwood and Wouxun radios have enough compliance to accept either a Wouxun or a Kenwood headset plug without complaint. Maybe it doesn’t matter?
Despite that, I made another gluing fixture with 11.5 mm spacing:
Plug alignment plate – 11.5 mm spacing
Those are 0.1 inch grids; it’s a little bitty block of smoke-gray polycarbonate from the scrap heap. The plugs are nominally 3.5 mm (which is not 1/8 inch in this universe) and 2.5 mm, with clearance drills #28 and #39.
Then I tried poking those 11.2 mm spaced plugs, now firmly epoxied in place in the yellow plate, and guess what: they don’t fit, no how no way. That’s not surprising, because there’s no compliance on either side of the joint and the plugs aren’t on the right centers for the fixture. Makes for a good No-Go gauge, I suppose.
However, I think I’ll tweak the solid model spacing to 11.5 mm and run off another plug mounting plate for the next radio.
FWIW, our ICOM IC-Z1A HTs use a sensible 10.0 mm spacing and that old fixture worked fine.
The sloppy hole fit lets the platen align to the tooling plate with the outer two 6-32 screws on the back edge.
Most of the PCB boards I make aren’t nearly as wide as the platen, which means the new SHCS won’t get in the way. The screws require a nut (as a spacer) to keep them from bottoming out on the Sherline’s table underneath the tooling plate and the washers are just because I can’t do it any other way; I should just shorten the screws and store them with the platen.
Masking tape holds small PCBs to the platen reasonably well, probably because I use an unreasonably high 50 mil travel clearance. I have a defunct dehumidifier that might make a dandy low-volume vacuum pump to eliminate any lifting in the middle: a project that has been on the to-do list for far too long…
Reassembling the mill provided an opportunity to move the Y axis Home switch from the rear of the axis to the front. The key discovery happened during the teardown: I can get the saddle off the Y axis dovetail by removing the gib, without sliding it off the front, which means a front switch can remain firmly glued in place.
A few random hunks of steel and a wire nut held the switch in position while the epoxy cured:
Mounting Y axis home switch
The switch actuator bottoms out with the saddle just touching the preload nut, so the saddle can’t dislodge the switch: the switch trips just before the saddle hits the nut, at which point all motion stops and the motor stalls.
Moving the switch means I can remove all the gimcrackery that poked the rear switch with the tooling plate in place; I was never happy with that setup. I also removed the small block that trapped the rear end of the Y leadscrew, under the assumption that, as I haven’t yet dropped anything on the leadscrew, I probably won’t. That adds about 1/4 inch to the maximum travel and allows the tooling plate to whack into the column.
The switch wire runs along the stepper cable, a tidy technique that hasn’t introduced any glitches into the shared Home signal from the X axis drivers:
Sherline mill – X and Y axis home switches
The Y axis now seeks the Home switch in the positive Y direction, so that stanza in Sherline.ini looks like this:
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
And from the 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();
}
Unlike the previous kludge, this GPS interface case resembles an extrusion with the PCBs sliding into place, held by setscrews along the edges of the slots:
HT-GPS Adapter Case – end view
Those errant threads seem to arise from not quite bonding to the corner. The battery side of the case (bottom in this view) is one thread wide, which isn’t quite enough. Adding another thread makes it 1 mm wide, which seems excessive.
The idea was to glue the battery interface plate on that side, but printing the case vertically puts various flaws along that surface:
HT-GPS Adapter Case – bottom view
So the next iteration will merge the battery plate with the case and print the whole affair in one shot. This view shows all the parts separately:
HT-GPS Adapter Case – exploded bottom view
This shows the case joined with the battery plate, neatly aligned for printing:
HT-GPS Adapter Case – combined battery interface
The battery plate has a 0.1 mm extension into the case to avoid problems from objects with coincident planes. Unfortunately, however, that means the intersection between the base plate and the shell forms a line with three planes extending from it: the two outside walls (which are co-planar) and the plate extension inside the case. Skeinforge sometimes complains mightily about that, despite my having applied a union() to fuse the plate with the case: obviously I don’t quite understand how union() works.
I think the battery contact holes will come out close enough to being right; they all have points on the top edge to reduce the overhang problem.
One gotcha: the actual metallic contact studs for the battery. The contacts for the ICOM IC-Z1A case came from carefully shaped brass screws secured by nuts above the PCB and that’s what I’ve been designing around for this case. Unfortunately, the PCB must slide in before installing the studs, which means reaching into the depths of the case, with all the wiring in the way, to turn those nuts. Fortunately, the PCB has plenty of clearance in that direction, but … it’ll be awkward at best.
The studs also need a slot / socket / dingus to prevent rotation while tightening the nuts; right now the contact plate is circular-ish, but maybe I should rethink that.
The Smell of Molten Projects in the Morning 