From e98868aecc7be5a9f4da5fcb8a10f74afe06b434 Mon Sep 17 00:00:00 2001
From: Luke Hubmayer-Werner <mongoose41@gmail.com>
Date: Tue, 4 Feb 2025 14:55:05 +1030
Subject: [PATCH] Adjusting locking tuner cutouts

---
 LockingGuitarTuner.scad | 42 +++++++++++++++++++++++++----------------
 common.scad             |  7 +++++++
 2 files changed, 33 insertions(+), 16 deletions(-)

diff --git a/LockingGuitarTuner.scad b/LockingGuitarTuner.scad
index f23f585..586b92e 100644
--- a/LockingGuitarTuner.scad
+++ b/LockingGuitarTuner.scad
@@ -1,5 +1,5 @@
 include <common.scad>
-module LockingGuitarTuner(holes=false) {
+module LockingGuitarTuner(holes=0) {
 	tolerance = 0.25;
 	d_post_cutout = 10.0 + tolerance;
 	h_post_cutout = 14.0;
@@ -20,29 +20,27 @@ module LockingGuitarTuner(holes=false) {
 	d_wormshaft_collar_max = 7.6;
 	$fn=72;
 
-	module tuner_footprint_extrude(h) {
-		// linear_extrude on tuner_footprint() segfaults for no reason
-		// src/openscad/src/geometry/linear_extrude.cc:409: std::unique_ptr<Geometry> extrudePolygon(const LinearExtrudeNode&, const Polygon2d&): Assertion `poly.isSanitized()' failed.
+	module tuner_footprint_extrude(h=t_base, tab_h=0, tolerance=0) {
+		h2 = (tab_h == 0) ? h : tab_h;
 		hull() {
-			translate([-w_tag/2, -l_tag+d_tag/2, 0]) cube([w_tag, l_tag-w_tag, h]);
-			cylinder(h=h, d=d_tag);
+			translate([0, -l_tag+d_tag/2 - tolerance, h/2]) cube([w_tag + tolerance, 0.00001, h], center=true);
+			cylinder(h=h, d=d_tag+tolerance);
+		}
+		rotate([0, 0, 45]) translate([0,0,h-h2]) hull() {
+			cylinder(h=h2, d=d_post_cutout + tolerance);
+			translate([0, 10.5]) cylinder(h=h2, d=screw_diameter+2 + tolerance);
 		}
 	}
 	module Holes() {
-		cylinder(d=d_post_cutout, h=h_post_cutout);
+		cylinder_beak(d=d_post_cutout, h=h_post_cutout);
 		rotate([0, 0, 45]) translate([0, 10.5]) linear_extrude(screw_depth) screw_hole_lobe(screw_diameter, screw_diameter+1, 5);
 	}
 
 	module TunerPreview() {
 		clear_color = [1,0,0,0.6];
-		color("grey") translate([0,0,-t_base]) tuner_footprint_extrude(t_base);
+		color("grey") translate([0,0,-t_base]) tuner_footprint_extrude(t_base, 2);
 		// screw
 		color(clear_color) rotate([0, 0, 45]) translate([0, 10.5]) cylinder(h=screw_depth, d=screw_diameter);
-		// screw tab
-		color("grey") rotate([0, 0, 45]) translate([0,0,-2]) hull() {
-			cylinder(h=2, d=d_post_cutout);
-			translate([0, 10.5]) cylinder(h=2, d=screw_diameter+2);
-		}
 		// peg
 		cylinder(h=h_post_cutout, d=d_post_cutout);
 		cylinder(h=h_post, d=d_post);
@@ -63,9 +61,21 @@ module LockingGuitarTuner(holes=false) {
 		}
 	}
 
-	if (holes)
+	if (holes > 0) {
+		t = t_base + holes;
 		Holes();
-	else
+		translate([0, 0, -t]) tuner_footprint_extrude(h=t, tolerance=0.5);
+		translate([w_tag/2, -l_tag+8-tolerance/2, -t]) cube([24, 8+tolerance, t]);
+	} else {
 		TunerPreview();
+	}
+}
+
+// translate([-12, 8]) LockingGuitarTuner();
+
+render() difference() {
+	t = 24;
+	cube([23, 48, t]);
+	translate([12, 10, t-14]) LockingGuitarTuner(holes=10);
+	translate([12, 34, t-14]) LockingGuitarTuner(holes=10);
 }
-// LockingGuitarTuner(holes=true);
diff --git a/common.scad b/common.scad
index 61c67a2..862c1c5 100644
--- a/common.scad
+++ b/common.scad
@@ -63,6 +63,13 @@ module screw_hole_lobe(ID, OD, lobes=3, fn=90) {
 	}
 }
 
+module cylinder_beak(d, h, beak=0.5) {
+	// A cylinder with a beak to take seams. This helps improve tolerances as seams often expand a little bit and ruin the fit.
+	cylinder(d=d, h=h);
+	// beak notch for seams
+	translate([0, d/2-beak*0.25, h/2]) rotate([0,0,45]) cube([beak, beak, h], center=true);
+}
+
 // We can't use Droid Sans Japanese because the rendering library is really dumb and will pick the wrong Droid Sans. CJK fonts must be singular files.
 JP_Serif_Font = "New Tegomin";
 JP_Sans_Font = "Yuji Boku";