add inner wall pieces that push out through their associated window

this looks kind of neat and helps the build feel of the horizontal
stripe windows, which were a bit flimsy without something sticking
through them

Signed-off-by: Brian S. Stephan <bss@incorporeal.org>

src/components.scad

@@ -352,14 +352,14 @@ module frame() {
 // for cutting out slashes from the frame outer wall
 module slash_cutout() {
 	polyhedron([
-		[slash_inner_displacement/2, -frame_wall/2, -slash_height/2],
-		[(slash_inner_displacement/2+slash_width), -frame_wall/2, -slash_height/2],
-		[(slash_inner_displacement/2+slash_width), frame_wall/2, -slash_height/2],
-		[slash_inner_displacement/2, frame_wall/2, -slash_height/2],
-		[-(slash_inner_displacement/2+slash_width), -frame_wall/2, slash_height/2],
-		[-slash_inner_displacement/2, -frame_wall/2, slash_height/2],
-		[-slash_inner_displacement/2, frame_wall/2, slash_height/2],
-		[-(slash_inner_displacement/2+slash_width), frame_wall/2, slash_height/2]
+		[slash_inner_displacement/2, -wall_cutout_depth, -slash_height/2],
+		[(slash_inner_displacement/2+slash_width), -wall_cutout_depth, -slash_height/2],
+		[(slash_inner_displacement/2+slash_width), wall_cutout_depth, -slash_height/2],
+		[slash_inner_displacement/2, wall_cutout_depth, -slash_height/2],
+		[-(slash_inner_displacement/2+slash_width), -wall_cutout_depth, slash_height/2],
+		[-slash_inner_displacement/2, -wall_cutout_depth, slash_height/2],
+		[-slash_inner_displacement/2, wall_cutout_depth, slash_height/2],
+		[-(slash_inner_displacement/2+slash_width), wall_cutout_depth, slash_height/2]
 	], [[0, 1, 2, 3], [4, 5, 1, 0], [7, 6, 5, 4], [5, 6, 2, 1], [6, 7, 3, 2], [7, 4, 0, 3]]);
 }
 

src/frames/pieces/front-or-back-inner-wall-for-horiz-stripes.scad

@@ -0,0 +1,32 @@
+/* The inner top/bottom wall of the frame, for being displayed through a horizontal stripe windowed part.
+ *
+ * SPDX-FileCopyrightText: © 2025 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+use <front-or-back-inner-wall.scad>
+use <front-or-back-longish.scad>
+use <front-or-back-windowed-horiz-stripes.scad>
+
+// for stability's sake, this piece juts out a bit from the outside of the wall, so we
+// need to hack the window piece a bit to subtract from the longer and get ours longer
+module horiz_striped_windowed_front_or_back_frame_piece() {
+	difference() {
+		front_or_back_longish_frame_piece();
+		// subtract frame wall windows
+		front_horiz_stripes();
+		// subtract the inner wall area that will be provided by the other piece
+		front_or_back_inner_wall_frame_piece();
+	}
+}
+
+module front_or_back_windowed_horiz_stripes_inner_wall_frame_piece() {
+	difference() {
+		front_or_back_longish_frame_piece();
+		horiz_striped_windowed_front_or_back_frame_piece();
+	}
+}
+
+front_or_back_windowed_horiz_stripes_inner_wall_frame_piece();

src/frames/pieces/front-or-back-longish.scad

@@ -0,0 +1,30 @@
+/*
+ * SPDX-FileCopyrightText: © 2025 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+use <front-or-back.scad>
+
+module front_or_back_frame_piece_wall() {
+	// get a slice of the whole wall, to use it for making the extended version
+	difference() {
+		front_or_back_frame_piece();
+		cube([frame_x, frame_y-frame_wall*2, frame_z], center=true);
+	}
+}
+
+module front_or_back_frame_piece_extension() {
+	hull() {
+		front_or_back_frame_piece_wall();
+		translate([0, -frame_bevel_height*2, 0]) front_or_back_frame_piece_wall();
+	}
+}
+
+module front_or_back_longish_frame_piece() {
+	front_or_back_frame_piece_extension();
+	front_or_back_frame_piece();
+}
+
+front_or_back_longish_frame_piece();

src/frames/pieces/front-or-back-windowed-horiz-stripes.scad

@@ -8,30 +8,26 @@ include <components.scad>
 use <front-or-back.scad>
 use <front-or-back-inner-wall.scad>
 
-module front_stripe() {
-	cube([frame_x-(frame_mount_column_width*1.75)*2, frame_wall, 5], center=true);
+module front_horiz_stripe() {
+	cube([frame_x-(frame_mount_column_width*1.75)*2, wall_cutout_depth, 5], center=true);
+}
+
+module front_horiz_stripes() {
+	translate([0, -(frame_y-frame_wall)/2, 18]) front_horiz_stripe();
+	translate([0, -(frame_y-frame_wall)/2, 9]) front_horiz_stripe();
+	translate([0, -(frame_y-frame_wall)/2, 0]) front_horiz_stripe();
+	translate([0, -(frame_y-frame_wall)/2, -9]) front_horiz_stripe();
+	translate([0, -(frame_y-frame_wall)/2, -18]) front_horiz_stripe();
 }
 
 module horiz_striped_windowed_front_or_back_frame_piece() {
 	difference() {
 		front_or_back_frame_piece();
 		// subtract frame wall windows
-		translate([0, -(frame_y-frame_wall)/2, 18]) front_stripe();
-		translate([0, -(frame_y-frame_wall)/2, 9]) front_stripe();
-		translate([0, -(frame_y-frame_wall)/2, 0]) front_stripe();
-		translate([0, -(frame_y-frame_wall)/2, -9]) front_stripe();
-		translate([0, -(frame_y-frame_wall)/2, -18]) front_stripe();
+		front_horiz_stripes();
 		// subtract the inner wall area that will be provided by the other piece
 		front_or_back_inner_wall_frame_piece();
 	}
 }
 
-module horiz_striped_windowed_front_or_back_frame_piece_for_extended_side() {
-	difference() {
-		horiz_striped_windowed_front_or_back_frame_piece();
-		// ...minus the frame wall and lip on the left
-		translate([-frame_x/2+frame_wall/2, 0, 0]) cube([frame_wall, frame_y, frame_z], center=true);
-	}
-}
-
-horiz_striped_windowed_front_or_back_frame_piece_for_extended_side();
+horiz_striped_windowed_front_or_back_frame_piece();

src/frames/pieces/side-inner-wall-for-horiz-stripes.scad

@@ -0,0 +1,32 @@
+/* The inner side wall of the frame, for being displayed through a horizontal stripe windowed part.
+ *
+ * SPDX-FileCopyrightText: © 2025 Brian S. Stephan <bss@incorporeal.org>
+ * SPDX-License-Identifier: GPL-3.0-or-later
+ */
+
+include <parameters.scad>
+include <components.scad>
+use <side-inner-wall.scad>
+use <side-longish.scad>
+use <side-windowed-horiz-stripes.scad>
+
+// for stability's sake, this piece juts out a bit from the outside of the wall, so we
+// need to hack the window piece a bit to subtract from the longer and get ours longer
+module horiz_striped_windowed_side_frame_piece() {
+	difference() {
+		side_longish_frame_piece();
+		// subtract frame wall windows
+		side_horiz_stripes();
+		// subtract the inner wall area that will be provided by the other piece
+		side_inner_wall_frame_piece();
+	}
+}
+
+module side_windowed_horiz_stripes_inner_wall_frame_piece() {
+	difference() {
+		side_longish_frame_piece();
+		horiz_striped_windowed_side_frame_piece();
+	}
+}
+
+side_windowed_horiz_stripes_inner_wall_frame_piece();

src/frames/pieces/side-longish.scad

@@ -5,34 +5,28 @@
 
 include <parameters.scad>
 include <components.scad>
-use <frames/complete/left-frame.scad>
 use <side.scad>
 
 module side_frame_piece_wall() {
-	// get a slice of the piece, to use it in extruding
-	// this doesn't use the side_frame_piece because of the 45 degree angle geometry
-	// not creating a clean thing to cut, so we just take the whole wall and use that
-	projection(cut=true) rotate([0, 90, 0]) translate([frame_x/2-frame_wall-(frame_bevel_height/2), 0, 0])
-		left_frame();
+	// get a slice of the whole wall, to use it for making the extended version
+	difference() {
+		side_frame_piece();
+		cube([frame_x-frame_wall*2, frame_y, frame_z], center=true);
+	}
 }
 
 module side_frame_piece_extension() {
-	// combine the original with a shrunken piece to "pull" the wall out
+	// hulling the two walls provides a wall with a thicker x
 	hull() {
-		linear_extrude(height=frame_bevel_height*4)
-			square([frame_z-(frame_bevel_height*2), frame_y-(frame_bevel_height*2)], center=true);
-		linear_extrude(height=frame_bevel_height*3) side_frame_piece_wall();
-		linear_extrude(height=frame_bevel_height) side_frame_piece_wall();
+		side_frame_piece_wall();
+		translate([-frame_bevel_height*2, 0, 0]) side_frame_piece_wall();
 	}
 }
 
 module side_longish_frame_piece() {
-	difference() {
-		side_frame_piece();
-		// chop off the old edge which is getting replaced with the extension
-		translate([-frame_x/2+frame_bevel_height/2, 0, 0]) cube([frame_bevel_height, frame_y, frame_z], center=true);
-	}
-	translate([-frame_x/2+frame_bevel_height*2, 0, 0]) rotate([0, -90, 0]) side_frame_piece_extension();
+	// combine the wider wall and the original piece
+	side_frame_piece_extension();
+	side_frame_piece();
 }
 
 side_longish_frame_piece();

src/frames/pieces/side-windowed-horiz-stripes.scad

@@ -8,19 +8,23 @@ include <components.scad>
 use <side.scad>
 use <side-inner-wall.scad>
 
-module side_stripe() {
-	cube([frame_wall, frame_y-(frame_mount_column_width*1.75)*2, 5], center=true);
+module side_horiz_stripe() {
+	cube([wall_cutout_depth, frame_y-(frame_mount_column_width*1.75)*2, 5], center=true);
+}
+
+module side_horiz_stripes() {
+	translate([-(frame_x-frame_wall)/2, 0, 18]) side_horiz_stripe();
+	translate([-(frame_x-frame_wall)/2, 0, 9]) side_horiz_stripe();
+	translate([-(frame_x-frame_wall)/2, 0, 0]) side_horiz_stripe();
+	translate([-(frame_x-frame_wall)/2, 0, -9]) side_horiz_stripe();
+	translate([-(frame_x-frame_wall)/2, 0, -18]) side_horiz_stripe();
 }
 
 module horiz_striped_windowed_side_frame_piece() {
 	difference() {
 		side_frame_piece();
 		// subtract frame wall windows
-		translate([-(frame_x-frame_wall)/2, 0, 18]) side_stripe();
-		translate([-(frame_x-frame_wall)/2, 0, 9]) side_stripe();
-		translate([-(frame_x-frame_wall)/2, 0, 0]) side_stripe();
-		translate([-(frame_x-frame_wall)/2, 0, -9]) side_stripe();
-		translate([-(frame_x-frame_wall)/2, 0, -18]) side_stripe();
+		side_horiz_stripes();
 		// subtract the inner wall area that will be provided by the other piece
 		side_inner_wall_frame_piece();
 	}

src/parameters.scad

@@ -104,6 +104,10 @@ neutrik_d_radius = 12 + hole_tolerance;
 decorative_radius_scale = 1.75;
 jumbo_decorative_radius_scale = 2;
 
+// decorative wall cutout parameters
+// thicker than the actual base wall to account for the longish pieces
+wall_cutout_depth = frame_wall * 3;
+
 // decorative slash parameters
 slash_inner_displacement = 10;
 slash_width = 15;