screw_tolerance=0.1; slide_tolerance=.3; play_tolerance=.8;
draft=true;
use <e3dchimera.scad>;

assembly_height = 49.5;		// the height of e3d chimera assembly in e3dchimera.scad
hs_nozzles_from_back = 6;	// the distance from nozzles from the back of the heatsink
hs_size = [30,18,30];		// the heatsink size
mounting_holes_from_top = [	// the offsets of mounting holes on the back
 [0, 20], [-4.5,10], [4.5,10]
];
mounting_holes_on_top = [	// the offsets of mounting holes on the top
 [0,-3], [-17/2,9], [17/2,9]
];
feeds_apart = 18;		// the distance between nozzles (and, therefore filament feeds)

feed_shell_d = 17;		// the shell diameter around filament feed, pushfit's diameter
screw_shell_d = 8;		// the shell diameter around screws
thread_h = 10.5;		// the height of the pushfit's thread
hinge_s = 6;			// hinges thickness

screwhead_d = 5.5;		// the diameter of the screw head
screwhead_h = 3;		// the height of the screw head

ms_size = [19.8,6,10];		// microswitch dimensions
ms_screws_apart = 9.5;		// distance between microswitch mounting screws
ms_switch_offset = 2.5;		// the offset of the switch from the center
ms_bump = ms_size[1];		// how far from hinge microswitch is mounted

lower_by = 15;			// lower hotend from the original intention by this long
gap = 5;			// gap between microswitch and heatsink

ps_offset = 3+3;		// pushscrew offset from the hinge

back_thickness = 8;		// thickness of the part behind the hinge
nut_thickness = 2.5;		// intelligent guess should suffice
nut_width = 5.5;		// intelligent guess should suffice

use <threads.scad>;
/* the internal thread for e3d bowden coupling: http://e3d-online.com/E3D-v6/Spares/Threaded-Bowden-Coupling-1.75mm-Filament */
module pushfit_thread(h=thread_h) {
 thr = 3/8 + .5/25.4;
 slit = 25.4*thr/2 + 0.4;
 translate([0,0,-1]) if(draft) cylinder(d=thr*25.4,h=h+2);
 else english_thread(diameter=thr,threads_per_inch=28,length=(h+2)/25.4,internal=true);
 translate([-2,-slit,-1]) cube([4,slit,h+2]);
}


sff = hs_nozzles_from_back+gap;			// switch from feeds
hff = sff+ms_size[1]+ms_bump+thread_h/2;	// hinges from feeds

module holder() {
 translate([0,0,0]) difference() {
  union() {
   hull() {
    rs = 3; drs = screw_shell_d/2-rs;
    rf = 6; drf = feed_shell_d/2-rf;
    for(sx=[-1,1]) translate([sx*feeds_apart/2,0,0]) {
     translate([0,0,drf])
     cylinder(d=feed_shell_d,h=thread_h-drf,$fn=60);
     cylinder(r=rf,h=thread_h,$fn=30);
    }
    for(mhot = mounting_holes_on_top) translate([mhot[0],mhot[1],0]) {
     translate([0,0,drs])
     cylinder(d=screw_shell_d,h=thread_h-drs,$fn=30);
     cylinder(r=rs,h=thread_h,$fn=30);
    }
   }
   hull() {
    translate([0,0,thread_h/2]) cube(size=[hs_size[0]-2*hinge_s-2*slide_tolerance,feed_shell_d,thread_h],center=true);
    translate([0,-hff,thread_h/2])
    rotate([0,90,0])
    cylinder(d=thread_h,h=hs_size[0]-2*hinge_s-2*slide_tolerance,center=true,$fn=60);
   }
  }//union
  for(sx=[-1,1]) translate([sx*feeds_apart/2,0,0])
   pushfit_thread();
  for(mhot = mounting_holes_on_top) translate([mhot[0],mhot[1],0]) {
   translate([0,0,-1]) cylinder(d=3,h=thread_h+2,$fn=12); // TODO: sink heads
   translate([0,0,thread_h/2]) cylinder(d=screwhead_d+slide_tolerance,h=thread_h/2+1,$fn=30);
  }
  // hinge
  translate([0,-hff,thread_h/2])
  rotate([0,90,0]) cylinder(d=3+slide_tolerance,h=hs_size[0],center=true,$fn=12);
  // push screw
  hull() for(oy=[-1,1]) translate([0,-hff+ps_offset+oy,-1]) cylinder(d=3+play_tolerance,h=thread_h+2,$fn=30);
  // tune screw
  translate([0,-sff-ms_size[1]/2,-1]) cylinder(d=3,h=thread_h+2);
 }//difference
}


module base() {
 us = 2*ms_size[2];
 translate([0,-hff,0]) difference() {
  union() {
   for(sx=[-1,1]) translate([sx*(hs_size[0]-hinge_s)/2,0,0]) hull() {
    translate([0,0,thread_h/2])
    rotate([0,90,0]) cylinder(d=thread_h,h=hinge_s,center=true,$fn=60);
    cube(size=[hinge_s,thread_h,thread_h],center=true);
    translate([-hinge_s/2,0,-1]) mirror([0,1,0]) cube(size=[hinge_s,thread_h/2+back_thickness,thread_h+1]);
   } // hull for
   hull() {
    translate([0,0,-us/2-slide_tolerance]) cube(size=[hs_size[0],thread_h+1,us],center=true);
    for(sx=[-1,1]) translate([sx*(hs_size[0]/2-ms_bump),thread_h/2,-us-slide_tolerance])
    cylinder(r=ms_bump,h=us+slide_tolerance,$fn=30);
   }
   translate([-hs_size[0]/2,-thread_h/2-slide_tolerance,-us-slide_tolerance])
   mirror([0,1,0]) cube(size=[hs_size[0],back_thickness,us+slide_tolerance+thread_h]);
  } // union
  translate([0,0,thread_h/2])
  rotate([0,90,0]) cylinder(d=3+screw_tolerance,h=hs_size[0]+2,center=true,$fn=12);
  for(smx=[0,1]) mirror([smx,0,0])
   translate([hs_size[0]/2+1,0,thread_h/2]) rotate([0,-90,0]) cylinder(d=screwhead_d+slide_tolerance,h=screwhead_h+1,$fn=30);
  /* changed my mind; for(srx=[-1,1]) rotate([srx*15,0,0])
   translate([0,0,thread_h/2-slide_tolerance])
   cube(size=[hs_size[0]-2*hinge_s,thread_h*sqrt(2)+2,thread_h],center=true); */
  // switch mount
  for(sx=[-1,1]) translate([sx*ms_screws_apart/2+ms_switch_offset,thread_h/2,-ms_size[2]])
   rotate([90,0,0])
   cylinder(d=2.5,h=ms_size[1]*2,center=true,$fn=12);
  // thing mount
  translate([0,-thread_h/2-back_thickness,lower_by])
  for(mhft = mounting_holes_from_top) translate([mhft[0],0,-mhft[1]]) {
   rotate([-90,0,0])
   translate([0,0,-1])
   cylinder(d=3,h=back_thickness+1);
   translate([0,back_thickness/2,0])
   cube(size=[2*hs_size[0],nut_thickness+slide_tolerance,nut_width+slide_tolerance],center=true);
  } // translate for
  mirror([0,0,1]) translate([0,ps_offset,-1]) cylinder(d=3,h=hs_size[2]+1);
 } // difference
}

view="*";

if(view=="holder") {
 holder();
}else if(view=="base") {
 base();
}else {
 % translate([0,0,-assembly_height]) chimera_assembly();
 color("lightgreen",0.7) holder();
 color("darkgreen",0.7) base();
}