Nunchuck now hangs more to accommodate case

.gitignore

@@ -11,3 +11,5 @@ Hardware/TataconUSB.PcbDoc.htm
 *.eep
 *.bin
 *.elf
+Firmware/Bootloader/
+*.hex

Hardware/Case/TataconCase.scad

@@ -1,8 +1,8 @@
 use <BezierScad.scad>
 
-fudge = 0.5;
+fudge = 0.4;
 
-board_length = 37.3 + fudge;
+board_length = 35.73 + fudge;
 board_width = 16.3 + fudge;
 board_thickness = 1.6;
 board_clearance_top = 3.3 + fudge; // height of crystal
@@ -25,17 +25,23 @@ switch_offsetx = 4.85;
 switch_offsety = 21.1;
 
 crystal_bottom = 18.3 + fudge;
+crystal_length = 11.4;
 
-wall_strength = 2;
+wall_strength = 1.6;
 
 lip_strength = 0.8;
 
 clip_height = 1.6;
+clip_strength = 1.6;
 
+cliplock_strength = 0.4;
+
+vertiLid = true;
 shapeways = false;
 shapeways_clearance = 1 + clip_height;
 
 $fn = 8;
+bezRes = 2;
 
 module board_shape(width = board_width, extend = 0) {
     translate([width,0,0])
@@ -54,7 +60,32 @@ module board_shape(width = board_width, extend = 0) {
         translate([board_height + board_clearance_top - bezHeight/2, crystal_bottom, 0])
             BezLine([
                 [0,-crystal_bottom/2], [0, bezWidth/2], [bezHeight, bezWidth/2], [bezHeight,bezWidth]
-                ], width = [bezHeight], resolution = 2, centered = true);
+                ], width = [bezHeight], resolution = bezRes, centered = true);
+    }
+}
+
+module clip(strength = clip_strength, height = clip_height, gap = fudge) {
+    // clip hang down
+    difference() {
+        // main body
+        // we want a tight fit so we only do half fudge
+        translate([gap/2, 0, 0])
+            board_shape(board_width - gap);
+        // form the lips
+        // Don't offset for the fudge above or we'll hit the Nunchuck
+        translate([strength,0,0])
+            board_shape(board_width - strength*2);
+        // cut them short
+        translate([0,0,-height])
+            board_shape(board_width, height);
+        // Shorten the front for clearance
+        cube([board_width, fudge, board_clearance_top*2]);
+        // Shorten the back for clearance
+        translate([0,board_length - fudge,0])
+            cube([board_width, fudge, board_clearance_top + nunchuck_height]);
+        // Cut out a hole for the crystal to go
+        translate([board_width-clip_strength, crystal_bottom - crystal_length, board_height])
+            cube([clip_strength, crystal_length, nunchuck_height + wall_strength]);
     }
 }
 
@@ -65,6 +96,7 @@ module lid() {
             translate([-wall_strength,0,0])
                 board_shape(board_width + wall_strength*2, wall_strength);
         };
+        
         // USB connector overhang
         usb_overhang = board_clearance_bottom+usb_relative_z+usb_height;
         translate([board_width/2 - usb_width/2,
@@ -73,16 +105,11 @@ module lid() {
         cube([usb_width,
               wall_strength,
               board_height+board_clearance_top - usb_overhang]);
-        // clip hang down
         difference() {
-            // main body
-            board_shape();
-            // form the lips
-            translate([wall_strength,0,0])
-                board_shape(board_width - wall_strength*2);
-            // cut them short
-            translate([0,0,-clip_height])
-                board_shape(board_width, clip_height);
+            clip();
+            // cutout for a locked fit
+            translate([0,0,-(clip_height/2 - cliplock_strength/2)])
+                clip(cliplock_strength, cliplock_strength);
         }
     }
 }
@@ -144,15 +171,24 @@ module button_hole() {
 module board() {
     // board shape minus the lid
     translate([wall_strength, wall_strength, wall_strength])
-    difference() {
-        hollowed();
-        port_holes();
-        lid();
+    union() {
+        difference() {
+            hollowed();
+            port_holes();
+            lid();
+        };
+        // clip points
+        translate([0,0,-(clip_height/2 - cliplock_strength/2)])
+            clip(cliplock_strength, cliplock_strength, 0);
     }
     // lid with reset button hole
     if(shapeways) {
         translate([wall_strength,wall_strength,wall_strength+shapeways_clearance])
         lid_complete();
+    } else if(vertiLid) {
+        rotate([90,0,90])
+        translate([wall_strength, wall_strength, -(board_height + nunchuck_height)])
+        lid_complete();
     } else {
         rotate([0,180,0])
         translate([wall_strength*3, wall_strength, -(board_height + nunchuck_height + wall_strength)])