router-template-cross-bar

// Router template for a cross bar
// A guide for routing a notch into a cross bar.

// Set Units
@settings(defaultLengthUnit = mm)

routerDiameter = 12.7
templateDiameter = 11 / 16 * inch()
templateGap = (templateDiameter - routerDiameter) / 2 - 0.5
slateWidthHalf = 41.5 / 2
minClampingDistance = 50 + 30
templateThickness = 10
radius = 10
depth = 30
distanceToInsideEdge = slateWidthHalf + templateThickness + templateGap
sketch001 = startSketchOn('XZ')
  |> startProfileAt([ZERO, depth + templateGap], %)
  |> xLine(length = slateWidthHalf - radius, tag = $seg01)
  |> arc({
       angleEnd = 0,
       angleStart = 90,
       radius = 10 + templateGap
     }, %, $seg09)
  |> yLine(endAbsolute = -templateThickness, tag = $seg03)
  |> xLine(length = templateThickness, tag = $seg07)
  |> yLine(endAbsolute = (segEndY(seg01) + templateThickness) / 2 - templateThickness, tag = $seg02)
  |> xLine(endAbsolute = segEndX(seg03) + minClampingDistance, tag = $seg06)
  |> yLine(length = templateThickness * 2, tag = $seg08)
  |> xLine(endAbsolute = segEndX(seg02) + 0, tag = $seg05)
  |> yLine(endAbsolute = segEndY(seg01) + templateThickness, tag = $seg10)
  |> xLine(endAbsolute = ZERO, tag = $seg04)
  |> xLine(length = -segLen(seg04))
  |> yLine(length = -segLen(seg10))
  |> xLine(length = -segLen(seg05))
  |> yLine(length = -segLen(seg08))
  |> xLine(length = segLen(seg06))
  |> yLine(length = -segLen(seg02))
  |> xLine(length = segLen(seg07))
  |> yLine(length = segLen(seg03))
  |> arc({
       angleEnd = 90,
       angleStart = 180,
       radius = 10 + templateGap
     }, %)
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
extrude001 = extrude(sketch001, length = 5)

sketch003 = startSketchOn(extrude001, 'START')
  |> startProfileAt([distanceToInsideEdge, 0], %)
  |> angledLine([180, templateThickness], %, $rectangleSegmentA002)
  |> angledLine([
       segAng(rectangleSegmentA002) + 90,
       templateThickness
     ], %, $rectangleSegmentB002)
  |> angledLine([
       segAng(rectangleSegmentA002),
       -segLen(rectangleSegmentA002)
     ], %, $rectangleSegmentC002)
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
extrude003 = extrude(sketch003, length = 13)

sketch002 = startSketchOn(extrude001, 'START')
  |> startProfileAt([-distanceToInsideEdge, 0], %)
  |> angledLine([0, templateThickness], %, $rectangleSegmentA001)
  |> angledLine([
       segAng(rectangleSegmentA001) - 90,
       templateThickness
     ], %, $rectangleSegmentB001)
  |> angledLine([
       segAng(rectangleSegmentA001),
       -segLen(rectangleSegmentA001)
     ], %, $rectangleSegmentC001)
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()

extrude002 = extrude(sketch002, length = 13)

sketch004 = startSketchOn(extrude002, 'END')
  |> startProfileAt([-distanceToInsideEdge, 0], %)
  |> angledLine([0, distanceToInsideEdge * 2], %, $rectangleSegmentA003)
  |> angledLine([
       segAng(rectangleSegmentA003) - 90,
       templateThickness
     ], %, $rectangleSegmentB003)
  |> angledLine([
       segAng(rectangleSegmentA003),
       -segLen(rectangleSegmentA003)
     ], %, $rectangleSegmentC003)
  |> line(endAbsolute = [profileStartX(%), profileStartY(%)])
  |> close()
extrude004 = extrude(sketch004, length = 4)