From 537e61d97b74827b6638849f1ab86772f2060a0e Mon Sep 17 00:00:00 2001
From: Jonathan Bernard <jonathan@jdbernard.com>
Date: Thu, 1 Jan 2026 10:57:15 -0600
Subject: [PATCH] Backpack Organizer v11: adjust lip clearance.

---
 backpack-organization/main-box.scad | 45 +++++++++++++++--------------
 1 file changed, 24 insertions(+), 21 deletions(-)

diff --git a/backpack-organization/main-box.scad b/backpack-organization/main-box.scad
index b3c6a8d..3f56fc8 100644
--- a/backpack-organization/main-box.scad
+++ b/backpack-organization/main-box.scad
@@ -6,7 +6,7 @@ $fn=128;
 outerWall=4;
 innerWall=2;
 layerClearance = 0.5;
-verStr="v10";
+verStr="v11";
 font="Montserrat";
 ep = 0.01; // smallest unit to ensure overlap between shapes
 
@@ -31,7 +31,7 @@ audioTrayIH = audioTrayHeight - innerWall;
 
 
 module shellBottom(dims) {
-  lipClearance = innerWall + 1;
+  lipClearance = innerWall + 0.2;
   bottomShellH = dims[2]*0.75;
   difference() {
     union() {
@@ -46,10 +46,10 @@ module shellBottom(dims) {
       }
 
       // add lip to mate with top
-      translate([lipClearance, lipClearance, bottomShellH - ep])
-      roundedCube(
-        [dims[0] - 2*lipClearance, dims[1] - 2*lipClearance, 4 - 1],
-        [2, 2, 0]);
+      translate([lipClearance, lipClearance, bottomShellH - 2])
+      chamferedCube(
+        [dims[0] - 2*lipClearance, dims[1] - 2*lipClearance, 6 - 1],
+        chamfer=1);
     }
 
     // carve out the interior
@@ -57,6 +57,7 @@ module shellBottom(dims) {
     cube([dims[0] - 2*outerWall, dims[1] - 2*outerWall, dims[2]]);
 
     // carve out a 0.6mm sliver for the fabric to sit in
+    /*
     fabricClearance = 0.6;
     translate([
       lipClearance - fabricClearance,
@@ -74,16 +75,16 @@ module shellBottom(dims) {
         [dims[0] - 2*lipClearance, dims[1] - 2*lipClearance, 8],
         [2, 2, 0]);
     }
+    */
 
     // version marker
     color("black")
-    translate([0.6, 20, 8]) rotate([90, 0,-90])
+    translate([0.6, 26, 8]) rotate([90, 0,-90])
     linear_extrude(0.61) text(text = verStr, font = font, size = 8);
   }
 }
 
 module shellTop(dims) {
-  lipClearance = innerWall + 1;
   topShellH = dims[2]*0.25;
   difference() {
     union() {
@@ -103,35 +104,37 @@ module shellTop(dims) {
     cube([dims[0] - 2*outerWall, dims[1] - 2*outerWall, dims[2]]);
 
     // carve out the interior of the lip
-    translate([lipClearance, lipClearance, topShellH])
-    roundedCube(
-      [dims[0] - 2*lipClearance, dims[1] - 2*lipClearance, dims[2]],
-      [2, 2, 0]);
+    translate([innerWall - 0.2, innerWall - 0.2, topShellH])
+    chamferedCube(
+      [dims[0] - 2*innerWall + 0.4, dims[1] - 2*innerWall + 0.4, dims[2]],
+      chamfer = 2);
 
+    /*
     // carve out a 0.6mm sliver for the fabric to sit in
     fabricClearance = 0.6;
     translate([
-      lipClearance,
-      lipClearance,
+      layerClearance,
+      layerClearance,
       topShellH - 4])
     difference() {
       roundedCube(
-        [ dims[0] - 2*lipClearance,
-          dims[1] - 2*lipClearance,
+        [ dims[0] - 2*layerClearance,
+          dims[1] - 2*layerClearance,
           7],
         [2, 2, 0]);
 
       translate([fabricClearance, fabricClearance, -ep])
       roundedCube(
-        [ dims[0] - 2*lipClearance - 2*fabricClearance,
-          dims[1] - 2*lipClearance - 2*fabricClearance,
+        [ dims[0] - 2*layerClearance - 2*fabricClearance,
+          dims[1] - 2*layerClearance - 2*fabricClearance,
           8],
         [2, 2, 0]);
     }
+    */
 
     // version marker
     color("black")
-    translate([0.6, 20, 8]) rotate([90, 0,-90])
+    translate([0.6, 26, 8]) rotate([90, 0,-90])
     linear_extrude(0.61) text(text = verStr, font = font, size = 8);
   }
 }
@@ -229,7 +232,7 @@ module layer1() {
 
       // version marker
       color("black")
-      translate([-innerWall + 0.6, 20, 4]) rotate([90, 0,-90])
+      translate([-innerWall + 0.6, 26, 4]) rotate([90, 0,-90])
       linear_extrude(0.61) text(text = verStr, font = font, size = 8);
     }
 
@@ -290,7 +293,7 @@ module layer2() {
 
       // version marker
       color("black")
-      translate([0.6, 20 + innerWall, 4]) rotate([90, 0,-90])
+      translate([0.6, 26 + innerWall, 4]) rotate([90, 0,-90])
       linear_extrude(0.61) text(text = verStr, font = font, size = 8);
     }