Fix Baseplate

Hole changes were not tested against it.
Many oppertunities for improvements here.

gridfinity-rebuilt-baseplate.scad

@@ -1,5 +1,6 @@
 include <gridfinity-rebuilt-utility.scad>
 include <standard.scad>
+use <gridfinity-rebuilt-holes.scad>
 
 // ===== INFORMATION ===== //
 /*
@@ -57,7 +58,6 @@ style_hole = 2; // [0:none, 1:countersink, 2:counterbore]
 
 
 // ===== IMPLEMENTATION ===== //
-screw_together = (style_plate == 3 || style_plate == 4);
 
 color("tomato")
 gridfinityBaseplate(gridx, gridy, l_grid, distancex, distancey, style_plate, enable_magnet, style_hole, fitx, fity);
@@ -75,7 +75,7 @@ module gridfinityBaseplate(gridx, gridy, length, dix, diy, sp, sm, sh, fitx, fit
     dx = max(gx*length-bp_xy_clearance, dix);
     dy = max(gy*length-bp_xy_clearance, diy);
 
-    off = calculate_off(sp, sm, sh);
+    off = calculate_offset(sp, sm, sh);
 
     offsetx = dix < dx ? 0 : (gx*length-bp_xy_clearance-dix)/2*fitx*-1;
     offsety = diy < dy ? 0 : (gy*length-bp_xy_clearance-diy)/2*fity*-1;
@@ -85,7 +85,7 @@ module gridfinityBaseplate(gridx, gridy, length, dix, diy, sp, sm, sh, fitx, fit
         mirror([0,0,1])
         rounded_rectangle(dx, dy, h_base+off, r_base);
 
-        gridfinityBase(gx, gy, length, 1, 1, 0, 0.5, false);
+        gridfinityBase(gx, gy, length, 1, 1, bundle_hole_options(), 0.5, false);
 
         translate([offsetx,offsety,h_base-0.6])
         rounded_rectangle(dx*2, dy*2, h_base*2, r_base);
@@ -105,33 +105,38 @@ module gridfinityBaseplate(gridx, gridy, length, dix, diy, sp, sm, sh, fitx, fit
 
 
                 hole_pattern(){
-                    if (sm) block_base_hole(1);
+                    if (sm) {
+                        mirror([0, 0, 1])
+                        block_base_hole(bundle_hole_options(magnet_hole=true));
+                    }
 
-                    translate([0,0,-off])
+                    translate([0,0,-off-TOLLERANCE])
                     if (sh == 1) cutter_countersink();
                     else if (sh == 2) cutter_counterbore();
                 }
             }
         }
-        if (sp == 3 || sp ==4) cutter_screw_together(gx, gy, off);
+        screw_together = sp == 3 || sp == 4;
+        if (screw_together) cutter_screw_together(gx, gy, off);
     }
 
 }
 
-function calculate_off(sp, sm, sh) =
-    screw_together
-        ? 6.75
-        :sp==0
-            ?0
-            : sp==1
-                ?bp_h_bot
-                :h_skel + (sm
-                    ?h_hole
-                    : 0)+(sh==0
-                        ? d_screw
-                        : sh==1
-                            ?d_cs
-                            :h_cb);
+function calculate_offset(style_plate, enable_magnet, style_hole) =
+    assert(style_plate >=0 && style_plate <=4)
+    let (screw_together = style_plate == 3 || style_plate == 4)
+    screw_together ? 6.75 :
+    style_plate==0 ? 0 :
+    style_plate==1 ? bp_h_bot :
+    calculate_offset_skeletonized(enable_magnet, style_hole);
+
+function calculate_offset_skeletonized(enable_magnet, style_hole) =
+    h_skel + (enable_magnet ? MAGNET_HOLE_DEPTH : 0) +
+    (
+        style_hole==0 ? d_screw :
+        style_hole==1 ? BASEPLATE_SCREW_COUNTERSINK_ADDITIONAL_RADIUS : // Only works because countersink is at 45 degree angle!
+        BASEPLATE_SCREW_COUNTERBORE_HEIGHT
+    );
 
 module cutter_weight() {
     union() {
@@ -156,23 +161,19 @@ module hole_pattern(){
 }
 
 module cutter_countersink(){
-    cylinder(r = r_hole1+d_clear, h = 100*h_base, center = true);
-    translate([0,0,d_cs])
-    mirror([0,0,1])
-    hull() {
-        cylinder(h = d_cs+10, r=r_hole1+d_clear);
-        translate([0,0,d_cs])
-        cylinder(h=d_cs+10, r=r_hole1+d_clear+d_cs);
-    }
+    screw_hole(SCREW_HOLE_RADIUS + d_clear, 2*h_base,
+        false, BASEPLATE_SCREW_COUNTERSINK_ADDITIONAL_RADIUS);
 }
 
 module cutter_counterbore(){
-    cylinder(h=100*h_base, r=r_hole1+d_clear, center=true);
+    screw_radius = SCREW_HOLE_RADIUS + d_clear;
+    counterbore_height = BASEPLATE_SCREW_COUNTERBORE_HEIGHT + 2*LAYER_HEIGHT;
+    union(){
+        cylinder(h=2*h_base, r=screw_radius);
         difference() {
-        cylinder(h = 2*(h_cb+0.2), r=r_cb, center=true);
-        copy_mirror([0,1,0])
-        translate([-1.5*r_cb,r_hole1+d_clear+0.1,h_cb-h_slit])
-        cube([r_cb*3,r_cb*3, 10]);
+            cylinder(h = counterbore_height, r=BASEPLATE_SCREW_COUNTERBORE_RADIUS);
+            make_hole_printable(screw_radius, BASEPLATE_SCREW_COUNTERBORE_RADIUS, counterbore_height);
+        }
     }
 }
 
@@ -185,7 +186,7 @@ module profile_skeleton() {
             translate([l_grid/2-d_hole_from_side,l_grid/2-d_hole_from_side,0])
             minkowski() {
                 square([l,l]);
-                circle(r_hole2+r_skel+2);
+                circle(MAGNET_HOLE_RADIUS+r_skel+2);
            }
         }
         circle(r_skel);

gridfinity-rebuilt-holes.scad

@@ -220,7 +220,7 @@ module screw_hole(radius, height, supportless=false, chamfer_radius=0, chamfer_a
  * @param chamfer Add a chamfer to the magnet hole.
  * @param supportless If the magnet hole should be printed in such a way that the screw hole does not require supports.
  */
-function bundle_hole_options(refined_hole=true, magnet_hole=false, screw_hole=false, crush_ribs=false, chamfer=false, supportless=false) =
+function bundle_hole_options(refined_hole=false, magnet_hole=false, screw_hole=false, crush_ribs=false, chamfer=false, supportless=false) =
     [refined_hole, magnet_hole, screw_hole, crush_ribs, chamfer, supportless];
 
 /**
@@ -230,6 +230,8 @@ function bundle_hole_options(refined_hole=true, magnet_hole=false, screw_hole=fa
  * @param o Offset
  */
 module block_base_hole(hole_options, o=0) {
+    assert(is_list(hole_options));
+
     // Destructure the options
     refined_hole = hole_options[0];
     magnet_hole = hole_options[1];

gridfinity-rebuilt-utility.scad

@@ -210,7 +210,7 @@ module profile_base() {
     ]);
 }
 
-module gridfinityBase(gx, gy, l, dx, dy, hole_options, off=0, final_cut=true, only_corners=false) {
+module gridfinityBase(gx, gy, l, dx, dy, hole_options=bundle_hole_options(), off=0, final_cut=true, only_corners=false) {
     dbnxt = [for (i=[1:5]) if (abs(gx*i)%1 < 0.001 || abs(gx*i)%1 > 0.999) i];
     dbnyt = [for (i=[1:5]) if (abs(gy*i)%1 < 0.001 || abs(gy*i)%1 > 0.999) i];
     dbnx = 1/(dx==0 ? len(dbnxt) > 0 ? dbnxt[0] : 1 : round(dx));

standard.scad

@@ -21,6 +21,10 @@ l_grid = 42;
 // Per spec, matches radius of upper base section.
 r_base = r_fo1;
 
+// Tollerance to make sure cuts don't leave a sliver behind,
+// and that items are properly connected to each other.
+TOLLERANCE = 0.01;
+
 // ****************************************
 // Magnet / Screw Hole Constants
 // ****************************************
@@ -50,9 +54,14 @@ MAGNET_HOLE_CRUSH_RIB_INNER_RADIUS = 5.9 / 2;
 // Anything 5 or under produces a hole that is not round.
 MAGNET_HOLE_CRUSH_RIB_COUNT = 8;
 
+// Radius to add when chamfering magnet and screw holes.
 CHAMFER_ADDITIONAL_RADIUS = 0.8;
 CHAMFER_ANGLE = 45;
 
+// When countersinking the baseplate, how much to add to the screw radius.
+BASEPLATE_SCREW_COUNTERSINK_ADDITIONAL_RADIUS = 5/2;
+BASEPLATE_SCREW_COUNTERBORE_RADIUS = 5.5/2;
+BASEPLATE_SCREW_COUNTERBORE_HEIGHT = 3;
 // ****************************************
 
 // top edge fillet radius
@@ -114,13 +123,7 @@ bp_rcut_length = 4.25;
 bp_rcut_depth = 2;
 // Baseplate clearance offset
 bp_xy_clearance = 0.5;
-// countersink diameter for baseplate
-d_cs = 2.5;
 // radius of cutout for skeletonized baseplate
 r_skel = 2;
-// baseplate counterbore radius
-r_cb = 2.75;
-// baseplate counterbore depth
-h_cb = 3;
 // minimum baseplate thickness (when skeletonized)
 h_skel = 1;