// Lawnmower washer square thing
// length units are millimeters
tolerance = 1.00;

topMetalWasherLength = 45.00 + tolerance; // this is (basically) square
innerShaftDiameter = 22.30;
bulbsLength = 32.40;
bulbsDiameter = 11.60;
bladeWidth = 44.40 + tolerance;
washerThickness = 3.00; // 2.00;
metalWasherThickness = 4.00; // 3.46;
bladeThickness = 2.50; // 2.24;

minGuideRidgeThickness = 8.00; // 3.00;

bladeBumpWidth = bladeWidth * 0.3333;
bladeBumpHeight = bladeThickness;

innerShaftRadius = innerShaftDiameter / 2;
bulbRadius = bulbsDiameter / 2;
washerLength = max(topMetalWasherLength, bladeWidth) + (minGuideRidgeThickness * 2);
bladeRidgeThickness = max(minGuideRidgeThickness, (washerLength - bladeWidth) / 2);
metalWasherRidgeThickness = max(minGuideRidgeThickness, (washerLength - topMetalWasherLength) / 2);

bladeBumpOffsetFromCenter = washerLength * 0.375;

circleResolution=360*4; // faces per rotation
zFightingOffset=0.01; // offset for shape subtraction

module shaft(height) {
    cylinder(r=innerShaftRadius, h=height, $fn=circleResolution);
    translate([-(bulbsLength - (bulbRadius * 2)) / 2,-bulbRadius,0])
        cube([bulbsLength - (bulbRadius * 2), bulbRadius * 2, height]);
    translate([innerShaftRadius, 0, 0])
        cylinder(r=bulbRadius, h=height, $fn=circleResolution);
    translate([-innerShaftRadius, 0, 0])
        cylinder(r=bulbRadius, h=height, $fn=circleResolution);
}

module bump(length, width, height) {
    translate([0, width/2, height])
        scale([length, width / 2, height])
            rotate([0, 90, 0])
                cylinder(r=1, h=1, $fn=circleResolution);
    translate([0, 0, height])
        cube([length, width, height + zFightingOffset]);
}

//bump(washerLength, bladeBumpWidth + zFightingOffset, washerThickness);

difference() {
    translate([-washerLength / 2, -washerLength / 2, 0]) {
        cube([washerLength, washerLength, washerThickness]);
        // blade ridges
        translate([0, washerLength / 2, washerThickness - zFightingOffset]) {
            translate([0, - (bladeWidth / 2) - bladeRidgeThickness,0])
                cube([washerLength, bladeRidgeThickness, bladeThickness]);
            translate([0, bladeWidth / 2,0])
                cube([washerLength, bladeRidgeThickness, bladeThickness]);
        }
        // metal washer ridges (standard)
        translate([washerLength / 2, 0, - metalWasherThickness + zFightingOffset]) {
            translate([-(topMetalWasherLength / 2) - metalWasherRidgeThickness, 0,0])
                cube([metalWasherRidgeThickness, washerLength, metalWasherThickness]);
            translate([topMetalWasherLength / 2,0,0])
                cube([metalWasherRidgeThickness, washerLength, metalWasherThickness]);
        }
        // metal washer ridges (optional)
        translate([0, washerLength / 2, - metalWasherThickness + zFightingOffset]) {
            translate([0, -(topMetalWasherLength / 2) - metalWasherRidgeThickness,0])
                cube([washerLength, metalWasherRidgeThickness, metalWasherThickness]);
            translate([0, topMetalWasherLength / 2,0])
                cube([washerLength, metalWasherRidgeThickness, metalWasherThickness]);
        }
    }
    translate([0,0,-zFightingOffset]) {
        // shaft
        rotate([0,0,0])
            shaft(washerThickness + (zFightingOffset * 2));
        // blade shaft bumps
        translate([0, -bladeBumpWidth/2, washerThickness - bladeBumpHeight]) {
            translate([-(washerLength + bladeBumpOffsetFromCenter), 0, 0])
                bump(washerLength, bladeBumpWidth + zFightingOffset, washerThickness);
            translate([bladeBumpOffsetFromCenter, 0, 0])
                bump(washerLength, bladeBumpWidth + zFightingOffset, washerThickness);
        }
    }
    /*
    // blade stand-in
    translate([-50, -bladeWidth/2, washerThickness])
        #cube([100, bladeWidth, bladeThickness]);
    // top metal washer stand-in
    translate([-topMetalWasherLength/2, -topMetalWasherLength/2, -metalWasherThickness])
        #cube([topMetalWasherLength, topMetalWasherLength, metalWasherThickness]);
    */
}