add eight screw holes to join the microphone body with the two flares, replaces the snap joints (which are still available through a configuration variable)

TinySpHEAR_mount_pcb.scad

@@ -105,7 +105,9 @@ box_radius = pcb_front + (pcb_thickness + pcb_tfit) + pcb_back + 2 * wall;
 // calculated main body corner radius
 mount_corner = box_radius - pcb_width / 2 + pcb_slot_depth + 4.0;
 
-// render span joints to join all three main assemblies
+//// snap joints to join the body to the two flares
+//
+// render snap joints to join all three main assemblies
 render_snap_joints = false;
 
 // body to flares snap joint arm slot width
@@ -115,6 +117,10 @@ snap_joint_slot_w = 0.75;
 snap_joint_hook_w = 5.0;
 snap_joint_hook_r = 1.4;
 
+//// screw holes to join the body to the two flares
+//
+render_screw_holes = true;
+
 // dimensions of 12 pin male bottom connector
 //
 // Amphenol T 3635 002
@@ -186,7 +192,17 @@ module tetra_mount_body(height, radius, corner, lower_lip, upper_lip, clear) {
             // remove slots from inside body
             slot_len = 30;
             translate([0, 0, slot_len]) {
+                difference() {
                     rounded_block_relative(height, radius, radius, corner, - (2 * wall));
+                    if (render_screw_holes) {
+                        // add columns for upper screw holes
+                        col_w = 3.5;
+                        for (r = [45, 135, 225, 315]) rotate([0, 0, r])
+                        translate([radius - col_w*2/3, -col_w/2, 0]) {
+                            cube([col_w, col_w, height]);
+                        }
+                    }
+                }
             }
             // upper lip for flare to microphone
             translate([0, 0, height - upper_lip]) {
@@ -202,6 +218,19 @@ module tetra_mount_body(height, radius, corner, lower_lip, upper_lip, clear) {
                     rounded_block_relative(lower_lip, radius, radius, corner, -(wall + lip_fit));
                 }
             }
+            if (render_screw_holes) {
+            // make eight holes in the the body for screws that hold both flares
+            // (number 0 size, 1/4" long = thread diameter: 1.6mm, head diameter: 2.75)
+                for (z = [lower_lip/2, height - upper_lip/2])
+                for (r = [45, 135, 225, 315]) {
+                    rotate([0, 0, r])
+                    translate([-(radius + 2 * wall), 0, z]) {
+                        rotate([0, 90, 0]) {
+                            cylinder(r = 0.7, h = radius + wall, $fn = facets);
+                        }
+                    }
+                }
+            }
             if (render_snap_joints) {
                 // slots for snap joint hooks
                 // lower
@@ -271,6 +300,17 @@ module tetra_mount_flare(height, lip, transition, bot_radius, bot_corner, top_ra
     difference() {
         union() {
             rounded_block(height, bot_radius, bot_radius, bot_corner);
+            if (render_screw_holes) {
+                // small supports for the screws that attach the flare to the body
+                // (number 0 size, 1/4" long = thread diameter: 1.6mm, head diameter: 2.75)
+                for (r = [45, 135, 225, 315]) rotate([0, 0, r]) {
+                    translate([bot_radius + wall/3, 0, lip/2]) {
+                        rotate([0, 90, 0]) {
+                            cylinder(r = 1.5, h = 2 * wall, $fn = facets);
+                        }
+                    }
+                }
+            }
             if (render_snap_joints) {
                 // make snap joint arm thicker
                 for (r = [0, 180]) rotate([0, 0, r]) {
@@ -283,6 +323,17 @@ module tetra_mount_flare(height, lip, transition, bot_radius, bot_corner, top_ra
         rounded_block_relative(height, bot_radius, bot_radius, bot_corner, -(2 * wall));
         // cut flange to mount on body
         rounded_block_relative(lip + 1.00, bot_radius, bot_radius, bot_corner, - (wall));
+        if (render_screw_holes) {
+            // holes for screws that attach the flare to the body
+            // Number 0 Size, 1/4" Long = thread diameter: 1.6mm, head diameter: 2.75
+            for (r = [45, 135, 225, 315]) rotate([0, 0, r]) {
+                translate([bot_radius + wall, 0, lip/2]) {
+                    rotate([0, 90, 0]) {
+                        cylinder(r = (1.6 + 0.1)/2, h = bot_radius, $fn = facets);
+                    }
+                }
+            }
+        }
         if (render_snap_joints) {
             // cut slots for snap joint hooks
             for (r = [0, 180]) rotate([0, 0, r]) {