1 files changed, 18 insertions, 26 deletions

diff --git a/another.scad b/another.scad
index 74b7ffa..78d4320 100644
--- a/another.scad
+++ b/another.scad
@@ -43,24 +43,25 @@ module the_extruder(
  mount_screwhead_d=6, mount_screwhead_h=3,
  idler_screw_d = 3,
  idler_screwhead_d=6, idler_screwhead_h=3,
 
  pf = pushfit_embeddest,
  pf_shell = max(3*layer_height,3*extrusion_width),
  pf_smooth = true,
 
  // empty spaces
          idler_travel = 3,                      // how far should idler travel when pressed
  idler_clearance=1,
  pulley_d_clearance=2,
+ pulley_small_d_clearance=0.5,
          lever_v_clearance=.7,                  // vertical clearance for the lever
  spring_d_clearance=1,
          protrusion_tolerance_h=.5,             // horizontal tolerance for the motor protrusion
          protrusion_tolerance_v=.5,             // vertical tolerance for the motor protrusion
  mount_screw_d_tolerance=.4,
  idler_v_tolerance=.5,
  knob_bore_d_tolerance=.6,
  st_nut_h_tolerance=.2,
  st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */
  st_screw_d_tolerance=.5,
  st_split_w_tolerance = .3,
 
@@ -318,58 +319,49 @@ module the_extruder(
     cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d);
    }//for
    // pushfit
    pf_offset = mount_d/sqrt(2)/2+mount_screw_d;
    translate([0,0,filament_elevation])
    rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0])
    rotate([-90,0,0])
    translate([0,0,pf_offset])
    rotate([0,0,180]) {
     pushfit(pf);
     mirror([0,0,1]) {
      fh = 1.5* (filament_guide_d-filament_path_d)/2;
-     fo = pf_offset-(idler_d+idler_clearance)/2-fh;
-     translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo-extrusion_width+1,angle=225);
+     fo = pf_offset -filament_path_d /*(idler_d+idler_clearance)/2*/-fh;
+     translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo/2,angle=225);
      translate([0,0,-1]) teardrop(d=filament_path_d,h=gearbox_d/2+1,angle=-225);
      translate([0,0,fo+epsilon])
      cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d);
     }//mirror
    }//rotate translate rotate translate rotate translate
    // pulley
-   cylinder(d=pulley_d+pulley_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance));
-   
-   // leverspace
-   hull() for(x=[0,gearbox_d])
-   rotate([0,0,45])
-   translate([x,0,ls_z-ls_h/2])
-   cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
-
-   // idler clearance
-   a=cos(45)*(pulley_d+idler_d)/2;
-   b=mount_d/2-a;
-   x=sqrt(pow(a,2)+pow(b,2));
-   translate([mount_d/2,0,ls_z])
-   intersection() {
-    r = x+idler_d/2+idler_clearance;
-    cylinder(r=r,h=ls_h,center=true);
-    translate([-r-1,0,-ls_h/2-1]) cube(size=[2*r+2,r+1,ls_h+2]);
-   }
+   cylinder(d=pulley_d+pulley_small_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance));
+   cylinder(d=pulley_d+pulley_d_clearance,ls_z-max(idler_h,filament_guide_d)/2,$fn=fnd*(pulley_d+pulley_d_clearance));
 
-   rotate([0,0,-45])
-   translate([0,0,ls_z-ls_h/2])
-   cube(size=[gearbox_d,gearbox_d,lever_thickness+lever_v_clearance]);
    translate([0,0,ls_z-ls_h/2]) {
-    translate([mount_screwhead_d/2,0,0])
-    mirror([0,1,0])
-    cube(size=[gearbox_d,gearbox_d/2+1,lever_thickness+lever_v_clearance]);
+    // idler travel
+    translate([mount_d/2,0,0])
+    rotate([0,0,45])
+    rotate_extrude(angle=90,$fn=fnr*(shortwing+(idler_d+idler_clearance)/2))
+    square([shortwing+(idler_d+idler_clearance)/2,ls_h]);
+    // idler itself
+    place_idler()
+    cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
+    // lever space
+    echo(atan(1-2*fsw/gearbox_d));
+    rotate([0,0,45])
+    rotate_extrude(angle=-135+max(atan(2*fsw/gearbox_d-1),atan(gearbox_d/mount_d-1)))
+    square([gearbox_d/2+1,ls_h]);
    }
 
    // back side cutout
    // XXX: this is somewhat ugly and potentially bugged,
    //      but I want to sleep.
    a0_ = atan(
     (mount_d/sqrt(2)/2+mount_screw_d+pf_h(pf)+gearbox_d/2)
     /
     (
      pulley_d/2+filament_offset-
      (pf_d(pf)+2*pf_shell)/2/cos(30)
     )