From 31e750b4d8f8183df79198576ad538d5414b9fc1 Mon Sep 17 00:00:00 2001
From: Cory Locklear <corylocklear@gmail.com>
Date: Sat, 13 Jun 2026 13:06:17 -0400
Subject: [PATCH] Added extra depth, ability to print front slice

---
 ring-solar-siding-adapter.scad | 42 ++++++++++++++++++++++++++--------
 1 file changed, 33 insertions(+), 9 deletions(-)

diff --git a/ring-solar-siding-adapter.scad b/ring-solar-siding-adapter.scad
index 1f81f21..b8e73ed 100644
--- a/ring-solar-siding-adapter.scad
+++ b/ring-solar-siding-adapter.scad
@@ -22,6 +22,7 @@ bead_coping_radius = 10.00;      // Semicircle radius for bead groove (measured
 bead_coping_offset_top = 11.00;  // Distance from plate top to groove center (tune on wall)
 flat_upper_ratio = 0.55;         // Fraction of plate height that stays flat at the top
 bottom_taper_depth_ratio = 1.6;  // Rear depth at plate bottom = min_wall_thickness * this (outward from flat shelf)
+rear_extension = 7.5;            // Extra depth toward wall; front face + bead groove stay fixed vs front/top
 course_pitch = 165.1;
 profile_segments = 8;
 profile_mode = "curved"; // [curved, stepped]
@@ -34,8 +35,9 @@ mount_hole_dia = 4.5;
 mount_hole_x = 0;
 
 /* [Export] */
-part_mode = "full"; // [full, profile_strip]
+part_mode = "full"; // [full, profile_strip, front_slice]
 profile_strip_width = 20;
+front_slice_depth = 3.5; // [2:0.5:8]
 
 /* [Hidden] */
 $fn = 64;
@@ -52,6 +54,9 @@ function projection_z() = siding_projection - rear_clearance;
 
 function face_inset_z() = projection_z() - face_inset_depth;
 
+// Flat rear shelf shifted toward the wall; bead groove keeps absolute depth at face_inset_z.
+function flat_rear_z() = face_inset_z() - rear_extension;
+
 function bead_coping_y_center() = plate_height - bead_coping_offset_top;
 
 // Bottom of flat rear shelf (flat_upper_ratio measured from plate top downward).
@@ -59,24 +64,23 @@ function face_y_flat_end() = plate_height * (1 - flat_upper_ratio);
 
 // Rear depth where the bottom taper ends (outward from flat shelf, in wall-thickness units).
 function bottom_rear_z() =
-    face_inset_z() + min_wall_thickness * bottom_taper_depth_ratio;
+    flat_rear_z() + min_wall_thickness * bottom_taper_depth_ratio;
 
-// Slow taper from bottom_rear_z at the plate bottom up to the flat shelf.
+// Slow taper from bottom_rear_z at the plate bottom up to the flat rear shelf.
 function lower_curve_z(y) =
     let(
         y1 = face_y_flat_end(),
         t = y / max(y1, epsilon),
         ease = pow(sin(t * 90), 1.4),
         z_bottom = bottom_rear_z(),
-        z_top = face_inset_z()
+        z_top = flat_rear_z()
     )
     z_top + (z_bottom - z_top) * (1 - ease);
 
 function stepped_rear_z(y) =
-    y >= face_y_flat_end() ? face_inset_z() : bottom_rear_z();
+    y >= face_y_flat_end() ? flat_rear_z() : bottom_rear_z();
 
-// Concave bead coping on the rear face near the plate top.
-// Flat chord at face_inset_z; arc scoops into the plate (toward the front).
+// Bead coping: fixed depth vs front/top. Flat chord at face_inset_z; arc scoops into plate.
 function bead_coping_rear_z(y) =
     let(
         r = bead_coping_radius,
@@ -84,7 +88,7 @@ function bead_coping_rear_z(y) =
         dy = y - bead_coping_y_center(),
         disc = r * r - dy * dy
     )
-    disc >= 0 ? shelf + sqrt(disc) : shelf;
+    disc >= 0 ? shelf + sqrt(disc) : flat_rear_z();
 
 // Flat top shelf + bead cavity + lower taper.
 function rear_z_at(y) =
@@ -109,7 +113,9 @@ function max_rear_z() =
     let(pts = rear_profile_points())
     max([for (p = pts) p[1]]);
 
-function front_z() = max_rear_z() + min_wall_thickness;
+// Front face anchored to bead groove + min wall (independent of rear_extension).
+function front_z() =
+    face_inset_z() + bead_coping_radius + min_wall_thickness;
 
 function rear_y_min() =
     min([for (p = rear_profile_points()) p[1]]);
@@ -170,6 +176,16 @@ module rounded_body(width) {
     }
 }
 
+// Keep only the front face cap for fit-checking width, height, and hole placement.
+module front_slice_mask(width) {
+    fz = front_z();
+    translate([plate_height / 2, fz - front_slice_depth / 2, 0])
+        cube(
+            [plate_height + 2 * epsilon, front_slice_depth + 2 * epsilon, width + 2 * epsilon],
+            center = true
+        );
+}
+
 module adapter_plate() {
     width = part_mode == "profile_strip" ? profile_strip_width : plate_width;
     if (part_mode == "full") {
@@ -177,6 +193,14 @@ module adapter_plate() {
             rounded_body(width);
             mount_holes();
         }
+    } else if (part_mode == "front_slice") {
+        intersection() {
+            difference() {
+                rounded_body(width);
+                mount_holes();
+            }
+            front_slice_mask(width);
+        }
     } else {
         rounded_body(width);
     }