fix: replace dovetail with bolted clamp mount

hardware/README.md

@@ -105,8 +105,9 @@ The ESP8266 and GoPro talk over Wi-Fi — **no data cable between them**. The on
 
 | | W × D × H (mm) |
 |---|---|
-| Case body external | ~56.8 × 42.0 × 19.2 |
+| Case body external | ~56.8 × 36.6 × 19.0 |
 | Lid external | ~56.8 × 32.8 × 4.0 |
-| Tripod clamp | ~43.0 × 54.5 × 16.0 |
+| Tripod clamp | ~43.0 × 53.5 × 16.0 |
+| Clamp-to-case mount | Two M3 screws through flat mounting plate |
 | Clamp pole fit | Nominal 35mm; smaller poles TBD / may need inserts |
 | Total weight | TBD after prototype print |

hardware/case/tripod-case-v3.scad

@@ -1,5 +1,5 @@
 // RemoteRig — Dual-ESP Tripod Case v3
-// v3 changes: screw-tightened tripod clamp + dovetail slide interface.
+// v3b changes: screw-tightened tripod clamp + two-screw flat mounting plate interface.
 // Coordinate system: all case/lid geometry uses bottom-origin Z.
 
 $fn = 36;
@@ -29,15 +29,16 @@ mouth_width   = 13.0;     // clamp opening
 m3_clearance  = 3.4;      // M3 screw clearance
 nut_flat      = 6.4;      // M3 nut trap flat-to-flat
 
-// Dovetail slide interface
+// Case ↔ clamp interface
-// Female receiver is on the case; male tab is on the tripod clamp.
+// v3b removes the dovetail: use a flat two-screw mounting plate instead.
-// This makes the separate parts visually/physically obvious: tab slides into slot.
+// This is simpler to print, easier to inspect, and field-serviceable.
-rail_z         = outer_h * 0.78;
+mount_plate_w      = 24.0;
-rail_depth     = 5.0;
+mount_plate_h      = 16.0;
-rail_neck_w    = 12.0;   // narrow side of the trapezoid profile
+mount_plate_thick  = 4.0;
-rail_outer_w   = 18.0;   // wide side of the trapezoid profile
+mount_hole_spacing = 10.0;
-rail_clearance = 0.55;   // FDM sliding clearance
+mount_screw_clear  = 3.4;  // M3 clearance through clamp plate
-socket_wall    = 2.2;
+mount_case_pilot   = 2.7;  // pilot/insert hole through case boss
+mount_boss_r       = 1.2;
 
 // Cable ports
 usb_port_w = 12; usb_port_h = 6;
@@ -107,30 +108,20 @@ module screw_post(x, y) {
     }
 }
 
-module case_dovetail_socket() {
+module case_mount_boss() {
-    // Receiver boss on the case back. A dovetail-shaped through-slot is cut
+    // Flat rear boss on the case. The clamp plate bolts directly to this face.
-    // vertically through it so the clamp's male tab slides down from above.
+    // Holes run front/back (Y axis) for M3 screws, heat-set inserts, or nuts.
-    socket_outer_w = rail_outer_w + socket_wall*2;
+    boss_y = outer_d/2 + mount_plate_thick/2 - 0.2;
-    socket_depth   = rail_depth + socket_wall*2;
-    boss_y0        = outer_d/2 - 0.15;
-
     difference() {
-        translate([0, boss_y0 + socket_depth/2, outer_h/2])
+        translate([0, boss_y, outer_h/2])
-            rounded_cube_centered(socket_outer_w, socket_depth, rail_z + socket_wall*2, 1.2);
+            rounded_cube_centered(mount_plate_w, mount_plate_thick, mount_plate_h, mount_boss_r);
 
-        // Through-cut, centered within the receiver boss, oversized for FDM.
+        for (zoff = [-mount_hole_spacing/2, mount_hole_spacing/2]) {
-        translate([0, boss_y0 + socket_wall, outer_h/2])
+            translate([0, outer_d/2 + mount_plate_thick/2, outer_h/2 + zoff])
-            dovetail_prism(
+                rotate([90, 0, 0])
-                rail_z + socket_wall*3,
+                    cylinder(d=mount_case_pilot, h=mount_plate_thick + wall*3, center=true, $fn=24);
-                rail_neck_w + rail_clearance,
+        }
-                rail_outer_w + rail_clearance,
-                rail_depth + rail_clearance
-            );
     }
-
-    // Bottom stop shelf: clamp tab slides down until it rests here.
-    translate([0, boss_y0 + socket_depth/2, outer_h*0.08])
-        rounded_cube_centered(socket_outer_w, socket_depth, 1.8, 0.8);
 }
 
 module case_body() {
@@ -138,7 +129,7 @@ module case_body() {
         case_shell();
         for (x = [-1, 1], y = [-1, 1])
             screw_post(x*(outer_w/2 - 5), y*(outer_d/2 - 5));
-        case_dovetail_socket();
+        case_mount_boss();
     }
 }
 
@@ -162,7 +153,7 @@ module clamp_ring_with_mouth() {
     outer_r = pole_dia/2 + clamp_thick;
     difference() {
         cylinder(r=outer_r, h=clamp_width, center=true, $fn=72);
-        cylinder(r=pole_dia/2 + rail_clearance, h=clamp_width + 1, center=true, $fn=72);
+        cylinder(r=pole_dia/2 + tol, h=clamp_width + 1, center=true, $fn=72);
         // Mouth opens toward +Y. Width is intentionally generous for snap-on placement before tightening.
         translate([0, outer_r, 0])
             cube([mouth_width, outer_r*2, clamp_width + 2], center=true);
@@ -189,25 +180,29 @@ module clamp_ears() {
     }
 }
 
-module clamp_male_dovetail_tab() {
+module clamp_mount_plate() {
     outer_r = pole_dia/2 + clamp_thick;
+    plate_y = -outer_r - mount_plate_thick/2 + 0.2;
 
-    // Positive tab on rear of clamp, opposite the tightening mouth. This is
+    // Flat plate matching the case boss. Two M3 clearance holes pass through
-    // intentionally the moving/replaceable side: it slides into the case socket.
+    // along Y so the clamp bolts to the case with ordinary hardware.
-    translate([0, -outer_r - rail_depth + 0.2, 0])
+    difference() {
-        dovetail_prism(
+        translate([0, plate_y, 0])
-            rail_z - rail_clearance,
+            rounded_cube_centered(mount_plate_w, mount_plate_thick, mount_plate_h, mount_boss_r);
-            rail_neck_w - rail_clearance,
+
-            rail_outer_w - rail_clearance,
+        for (zoff = [-mount_hole_spacing/2, mount_hole_spacing/2]) {
-            rail_depth - 0.25
+            translate([0, plate_y, zoff])
-        );
+                rotate([90, 0, 0])
+                    cylinder(d=mount_screw_clear, h=mount_plate_thick + 2, center=true, $fn=24);
+        }
+    }
 }
 
 module tripod_clamp() {
     union() {
         clamp_ring_with_mouth();
         clamp_ears();
-        clamp_male_dovetail_tab();
+        clamp_mount_plate();
     }
 }