Simplified setup by removing extra_small; made the body the same diam…

…eter as a vac manifold

README.md

@@ -29,7 +29,7 @@ And one-time requirements:
 
 3. Measure your boring bar and trim it if necessary.
 
-   For Makita: The optimal length is with 3.5" bar but it can be longer, or shorter like 3". The least expensive options on the market are 6" long boring bars, but while they will work, it's better to have them trimmed to 3" or 3.5" to decrease vibration and make more compact adapters. Don't trim your bars less than 3", but you can use "short_threads" set to 1 to make a shorter adapter if your length is less than 3.2". 2.8" is the shortest you could go unless you use "extra_short = 1", in which case, you could go as low as 2.55" but it wouldn't be really convenient and most likely, you won't be able to use any other station. Shorter bar means less vibration.
+   For Makita: The optimal length is with 3.5" bar but it can be longer, or shorter like 3". The least expensive options on the market are 6" long boring bars, but while they will work, it's better to have them trimmed to 3" or 3.5" to decrease vibration and make more compact adapters. Don't trim your bars less than 3", but you can use "short_threads" set to 1 to make a shorter adapter if your length is less than 3.2". You could go as low as 2.55" but it wouldn't be really convenient and most likely, you won't be able to use any other station. Shorter bar means less vibration.
 
    For DRILL MASTER: Your boring bar should be at least 2.55" long. Again, shorter bar means less vibration.
 

TrimmerAdapter.scad

@@ -52,37 +52,34 @@ tight_threads = 1;
 // But it's always better to use a shorter boring bar.
 additional_height = 0; // in mm
 
-// Setting "extra_short" to 1 will allow to use really short boring bars with
-// Makita routers. It will not work with Drill Master (but its design already
-// allows shorter bars).
-extra_short = 0;
-
 /*****************************************************************************
  * NO SERVICEABLE PARTS BELOW. ENTER AT YOUR OWN RISK
  ****************************************************************************/
+spaces = "                ";
+
+echo(str("Calculating for bar length = ", bar_length, "mm", spaces));
 
 mm_in_in = 25.4;
 fn = 120; // slower rendering once, nicer look every day
 threads_size = 13 / 16 * mm_in_in; // 20.6375mm
-threads_length = short_threads || extra_short ? threads_size * 0.5 : threads_size; // not less than the length of threads on the trim die
+threads_length = short_threads ? threads_size * 0.5 : threads_size; // not less than the length of threads on the trim die
 max_bar = 14; // how long the bar extends below the threads. May depend upon the trim die and your preferred trim length
 
 is_makita = router_type == "makita" ? 1 : 0;
 is_dm2hp = is_makita ? 0 : 1;
 
-if (is_dm2hp) {
-    assert(! extra_short, "extra_short will not work with Drill Master");
-}
-
 bolt_hole_height = 30; // for mounting holes, should be more than the base_height
-center_hole = extra_short ? 30 : 32; // the opening at the very bottom, can be increased if more clearance is needed or decreased if your boring bar is too short.
-main_body_inside_diameter = extra_short ? 30 : 32;
+center_hole = 32; // the opening at the very bottom, can be increased if more clearance is needed or decreased if your boring bar is too short.
+main_body_inside_diameter = 32;
 
 base_height = 10;   //
-body_thickness = 2;
-body_diameter = main_body_inside_diameter + 2 * body_thickness; // outer diameter of the tube
+body_thickness = 4;
+extra_wall = 2;
+body_diameter = is_body_only
+ ? main_body_inside_diameter + 2 * extra_wall      // body_only is narrower
+ : main_body_inside_diameter + 2 * body_thickness; // outer diameter of the tube shoud be 40mm
 
-spaces = "                "; 
+echo(str("body diameter = ", body_diameter, spaces));
 
 // DM2hp router needs more space to fit the chuck nut, change the angle of the top cone
 taper_cone_angle = is_dm2hp ? 60 : 45;
@@ -103,7 +100,7 @@ assert(threads_size < main_body_inside_diameter);
 
 body_height = bar_length - holder_depth - max_bar;
 
-min_bar_length = threads_length + max_bar + holder_depth + min_height;
+min_bar_length = max_bar + holder_depth + min_height;
 echo(str("min_bar_length = ", min_bar_length, "mm (", min_bar_length / mm_in_in, "in)", spaces));
 
 echo(str("body height is ", body_height, spaces));