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// n0nce's Steel Washer backup jig
// ---------- configuration ---------- //
washer_dia = 30; // set to your washer's diameter (mm)
washer_hole = 10.5; // set to your washer's hole diameter (mm)
washer_h = 3; // set to your washer's thickness (mm)
stamp_w = 8; // set to your stamp's width (mm)
stamp_d = 8; // set to your stamp's depth (mm)
// ---------- code ---------- //
tolerance = 0.25;
// ---------- outer part ---------- //
module roundedcube(xx, yy, height, radius) {
$fn=60;
translate([0,0,height/2])
hull() {
translate([radius,radius,0])
cylinder(height,radius,radius,true);
translate([xx-radius,radius,0])
cylinder(height,radius,radius,true);
translate([xx-radius,yy-radius,0])
cylinder(height,radius,radius,true);
translate([radius,yy-radius,0])
cylinder(height,radius,radius,true);
}
}
module washer() {
cylinder(h=washer_h, r=washer_dia/2, center=false, $fn=200);
}
module outer() {
module outer_body() {
translate([-27, -27, 0])
roundedcube(54, 54, 20, 3);
}
module slot() {
translate([-5/2,0,washer_h])
cube([5,23,30]);
}
difference(){
outer_body();
// main cylinder to cut out
translate([0, 0, washer_h])
cylinder(h=100, r=38/2, center=false, $fn=200);
// washer cut out
translate([0, 0, -1])
scale([1, 1, 10])
washer();
// number slots cut outs
for (i=[0,2])
rotate(-14+i*14)
slot();
// letter slots cut outs
for (i=[0:7])
rotate(82+i*28)
slot();
}
}
// ---------- inner part ---------- //
module inner() {
module inner_body() {
// main part
cylinder(h=20-washer_h, r=38/2-0.3, center=false, $fn=200);
// handle
cylinder(h=20-washer_h+8, d=9, center=false, $fn=200);
// sticking out part
rotate(-14) translate([-4/2,0,0])
cube([4,22.5,20-washer_h]);
}
module puncher_hole() {
sw=stamp_w+tolerance;
sd=stamp_d+tolerance;
rotate(-14) translate([-sw/2,
(washer_dia+washer_hole)/4-sd/2,
-10])
cube([sw,sd,50]);
}
translate([0, 0, washer_h]) {
difference() {
inner_body();
puncher_hole();
}
}
}
outer();
translate([70,0,0])
inner();