fix: enlarge case for selected ESP modules and wiring

go.mod

@@ -12,12 +12,9 @@ require (
 require (
 	github.com/dustin/go-humanize v1.0.1 // indirect
 	github.com/google/uuid v1.6.0 // indirect
-	github.com/gorilla/websocket v1.5.3 // indirect
 	github.com/mattn/go-isatty v0.0.20 // indirect
 	github.com/ncruces/go-strftime v1.0.0 // indirect
 	github.com/remyoudompheng/bigfft v0.0.0-20230129092748-24d4a6f8daec // indirect
-	golang.org/x/net v0.27.0 // indirect
-	golang.org/x/sync v0.20.0 // indirect
 	golang.org/x/sys v0.42.0 // indirect
 	modernc.org/libc v1.72.3 // indirect
 	modernc.org/mathutil v1.7.1 // indirect

go.sum

@@ -1,15 +1,11 @@
 github.com/dustin/go-humanize v1.0.1 h1:GzkhY7T5VNhEkwH0PVJgjz+fX1rhBrR7pRT3mDkpeCY=
 github.com/dustin/go-humanize v1.0.1/go.mod h1:Mu1zIs6XwVuF/gI1OepvI0qD18qycQx+mFykh5fBlto=
-github.com/eclipse/paho.mqtt.golang v1.5.0 h1:EH+bUVJNgttidWFkLLVKaQPGmkTUfQQqjOsyvMGvD6o=
-github.com/eclipse/paho.mqtt.golang v1.5.0/go.mod h1:du/2qNQVqJf/Sqs4MEL77kR8QTqANF7XU7Fk0aOTAgk=
 github.com/go-chi/chi/v5 v5.2.5 h1:Eg4myHZBjyvJmAFjFvWgrqDTXFyOzjj7YIm3L3mu6Ug=
 github.com/go-chi/chi/v5 v5.2.5/go.mod h1:X7Gx4mteadT3eDOMTsXzmI4/rwUpOwBHLpAfupzFJP0=
 github.com/google/pprof v0.0.0-20250317173921-a4b03ec1a45e h1:ijClszYn+mADRFY17kjQEVQ1XRhq2/JR1M3sGqeJoxs=
 github.com/google/pprof v0.0.0-20250317173921-a4b03ec1a45e/go.mod h1:boTsfXsheKC2y+lKOCMpSfarhxDeIzfZG1jqGcPl3cA=
 github.com/google/uuid v1.6.0 h1:NIvaJDMOsjHA8n1jAhLSgzrAzy1Hgr+hNrb57e+94F0=
 github.com/google/uuid v1.6.0/go.mod h1:TIyPZe4MgqvfeYDBFedMoGGpEw/LqOeaOT+nhxU+yHo=
-github.com/gorilla/websocket v1.5.3 h1:saDtZ6Pbx/0u+bgYQ3q96pZgCzfhKXGPqt7kZ72aNNg=
-github.com/gorilla/websocket v1.5.3/go.mod h1:YR8l580nyteQvAITg2hZ9XVh4b55+EU/adAjf1fMHhE=
 github.com/hashicorp/golang-lru/v2 v2.0.7 h1:a+bsQ5rvGLjzHuww6tVxozPZFVghXaHOwFs4luLUK2k=
 github.com/hashicorp/golang-lru/v2 v2.0.7/go.mod h1:QeFd9opnmA6QUJc5vARoKUSoFhyfM2/ZepoAG6RGpeM=
 github.com/mattn/go-isatty v0.0.20 h1:xfD0iDuEKnDkl03q4limB+vH+GxLEtL/jb4xVJSWWEY=
@@ -20,8 +16,6 @@ github.com/remyoudompheng/bigfft v0.0.0-20230129092748-24d4a6f8daec h1:W09IVJc94
 github.com/remyoudompheng/bigfft v0.0.0-20230129092748-24d4a6f8daec/go.mod h1:qqbHyh8v60DhA7CoWK5oRCqLrMHRGoxYCSS9EjAz6Eo=
 golang.org/x/mod v0.33.0 h1:tHFzIWbBifEmbwtGz65eaWyGiGZatSrT9prnU8DbVL8=
 golang.org/x/mod v0.33.0/go.mod h1:swjeQEj+6r7fODbD2cqrnje9PnziFuw4bmLbBZFrQ5w=
-golang.org/x/net v0.27.0 h1:5K3Njcw06/l2y9vpGCSdcxWOYHOUk3dVNGDXN+FvAys=
-golang.org/x/net v0.27.0/go.mod h1:dDi0PyhWNoiUOrAS8uXv/vnScO4wnHQO4mj9fn/RytE=
 golang.org/x/sync v0.20.0 h1:e0PTpb7pjO8GAtTs2dQ6jYa5BWYlMuX047Dco/pItO4=
 golang.org/x/sync v0.20.0/go.mod h1:9xrNwdLfx4jkKbNva9FpL6vEN7evnE43NNNJQ2LF3+0=
 golang.org/x/sys v0.6.0/go.mod h1:oPkhp1MJrh7nUepCBck5+mAzfO9JrbApNNgaTdGDITg=

hardware/README.md

@@ -1,7 +1,7 @@
 # RemoteRig — Camera Node Hardware Design
 
 > **Version:** 0.2.0 | **Status:** Draft  
-> **Target:** GoPro Hero 3 Black/Silver + ESP8266 + ESP32 + USB power bank
+> **Target:** GoPro Hero 3 Black/Silver + ESP-01S/ESP8266 + ESP32-C3 Super Mini + USB power bank
 
 ## Overview
 
@@ -29,8 +29,8 @@ Each camera node is two ESP boards in a small case that clips to the tripod/stan
 
 | Item | Qty | Cost | Notes |
 |------|-----|------|-------|
-| ESP32 Dev Board | 1 | ~$5 | MQTT bridge — talks to hub |
+| ESP32-C3 Super Mini | 1 | ~$5 | MQTT bridge — talks to hub; board footprint 22.5 × 18.0mm |
-| ESP8266 D1 Mini | 1 | ~$3 | Camera bridge — talks to GoPro |
+| ESP-01S / ESP8266 | 1 | ~$3 | Camera bridge — talks to GoPro; module envelope 24.7 × 14.3 × 12.0mm |
 | USB power bank (5000mAh+) | 1 | ~$10 | Powers both boards + GoPro |
 | Micro-USB cable (short) | 2 | ~$2 | Power bank → boards + GoPro |
 | Jumper wires F-F | 3 | ~$0.25 | UART TX/RX/GND between boards |
@@ -45,8 +45,8 @@ Each camera node is two ESP boards in a small case that clips to the tripod/stan
 **Pipeline:** `hardware/DESIGN_PIPELINE.md`
 
 Four exported prototype files:
-1. **Case body** — holds both boards stacked, cable ports, rear dovetail-style receiver
+1. **Case body** — holds both boards side-by-side with extra wiring/service clearance, cable ports, rear mounting boss
-2. **Case lid** — screw-on cover with ventilation
+2. **Case lid** — screw-on cover with ventilation and underside locating lip for flush seating
 3. **Tripod clamp** — separate screw-tightened C-clamp sized around a 35mm stand/pole
 4. **Full preview** — combined visualization STL only, not intended as the print job
 
@@ -105,8 +105,11 @@ The ESP8266 and GoPro talk over Wi-Fi — **no data cable between them**. The on
 
 | | W × D × H (mm) |
 |---|---|
-| Case body external | ~56.8 × 38.2 × 19.0 |
+| Board envelope basis | ESP32-C3 Super Mini: 22.5 × 18.0; ESP-01S: 24.7 × 14.3 × 12.0 |
-| Lid external | ~56.8 × 32.8 × 4.0 |
+| Internal CAD allowance | ~71.2 × 34.0 × 22.0; intentionally includes wiring gutters and vertical connector clearance |
-| Tripod clamp | ~43.0 × 56.9 × 16.0 |
+| Case body external | ~76.0 × 42.6 × 26.0 including rear mount boss depth; main shell ~76.0 × 38.8 × 26.0 |
+| Lid external | ~76.0 × 38.8 × 3.6; includes 1.6mm underside locating lip |
+| Tripod clamp | ~43.0 × 53.5 × 16.0 |
+| Clamp-to-case mount | Two side-by-side 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

@@ -1,26 +1,39 @@
 // RemoteRig — Dual-ESP Tripod Case v3
-// v3 changes: screw-tightened tripod clamp + dovetail slide interface.
+// v3e changes: board-specific envelope for ESP32-C3 Super Mini + ESP-01S with wiring clearance.
 // Coordinate system: all case/lid geometry uses bottom-origin Z.
 
 $fn = 36;
 
-// Board dimensions
+// Board dimensions from selected modules.
-esp8266_w = 34.2; esp8266_d = 25.6; esp8266_h = 5;
+// ESP32-C3 Super Mini: 22.5 x 18.0 mm footprint.
-esp32_w   = 52;   esp32_d   = 28;   esp32_h   = 5;
+// ESP-01S / ESP8266:   24.7 x 14.3 x 12.0 mm envelope.
-board_gap = 3;
+// The case is intentionally larger than board footprints because the field
-stack_h   = esp8266_h + esp32_h + board_gap;
+// build needs room for Dupont/UART wiring, power leads, bend radius, and fingers.
-inner_w   = max(esp8266_w, esp32_w);
+esp32c3_w = 22.5; esp32c3_d = 18.0; esp32c3_h = 6.0;   // height allowance includes headers/pins TBD
-inner_d   = max(esp8266_d, esp32_d);
+esp01s_w  = 24.7; esp01s_d  = 14.3; esp01s_h  = 12.0;
-inner_h   = stack_h + 2;
+board_gap = 8.0;     // side-by-side service gap between boards
+wire_x    = 8.0;     // wiring gutter at left/right ends
+wire_y    = 8.0;     // wiring gutter along front/back edges
+wire_z    = 10.0;    // vertical wiring/connector clearance above tallest module
+
+inner_w   = esp32c3_w + esp01s_w + board_gap + wire_x*2;
+inner_d   = max(esp32c3_d, esp01s_d) + wire_y*2;
+inner_h   = max(esp32c3_h, esp01s_h) + wire_z;
 
 // Case parameters
 wall     = 2.0;
 tol      = 0.4;
-outer_w  = inner_w + wall*2 + tol*2;      // 56.8mm
+outer_w  = inner_w + wall*2 + tol*2;      // 76.0mm with current board/wiring envelope
-outer_d  = inner_d + wall*2 + tol*2;      // 32.8mm
+outer_d  = inner_d + wall*2 + tol*2;      // 38.8mm with current board/wiring envelope
-outer_h  = inner_h + wall*2;              // 19mm
+outer_h  = inner_h + wall*2;              // 26.0mm with current board/wiring envelope
 corner_r = 2.5;
 
+// Lid fit parameters
+lid_top_thick = 2.0;
+lid_lip_h     = 1.6;
+lid_clearance = 0.6;   // clearance around underside locating lip
+lid_lip_wall  = 1.2;   // thickness of perimeter lip/frame
+
 // Tripod clamp parameters
 pole_dia      = 35;       // nominal stand/pole diameter
 clamp_thick   = 4.0;      // ring wall thickness
@@ -29,15 +42,16 @@ 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
-// Male rail is on the case; matching female socket is on the tripod clamp.
+// v3b removes the dovetail: use a flat two-screw mounting plate instead.
-// This is easier to inspect and avoids the previous mismatched "two lips + tab" geometry.
+// 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 width at case wall / slot opening
+mount_plate_thick  = 4.0;
-rail_outer_w   = 18.0;   // wider retained edge
+mount_hole_spacing = 14.0;  // side-by-side M3 case-mount screws
-rail_clearance = 0.45;   // FDM sliding clearance per side-ish
+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;
@@ -107,15 +121,20 @@ module screw_post(x, y) {
     }
 }
 
-module case_male_dovetail_rail() {
+module case_mount_boss() {
-    // Positive tapered rail on the case back. Cross-section is narrow at the
+    // Flat rear boss on the case. The clamp plate bolts directly to this face.
-    // wall and wider at the outside, so the clamp socket captures it.
+    // Holes run front/back (Y axis) for M3 screws, heat-set inserts, or nuts.
-    translate([0, outer_d/2 - 0.15, outer_h/2])
+    boss_y = outer_d/2 + mount_plate_thick/2 - 0.2;
-        dovetail_prism(rail_z, rail_neck_w, rail_outer_w, rail_depth);
+    difference() {
+        translate([0, boss_y, outer_h/2])
+            rounded_cube_centered(mount_plate_w, mount_plate_thick, mount_plate_h, mount_boss_r);
 
-    // Bottom stop so the clamp socket cannot slide past the case.
+        for (xoff = [-mount_hole_spacing/2, mount_hole_spacing/2]) {
-    translate([0, outer_d/2 + rail_depth/2, outer_h*0.12])
+            translate([xoff, outer_d/2 + mount_plate_thick/2, outer_h/2])
-        rounded_cube_centered(rail_outer_w + 3.0, rail_depth + 0.8, 2.4, 0.8);
+                rotate([90, 0, 0])
+                    cylinder(d=mount_case_pilot, h=mount_plate_thick + wall*3, center=true, $fn=24);
+        }
+    }
 }
 
 module case_body() {
@@ -123,22 +142,48 @@ 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_male_dovetail_rail();
+        case_mount_boss();
     }
 }
 
+module lid_locating_lip() {
+    // Thin underside frame that drops into the case opening. This registers the
+    // lid so it cannot skate/rock on the rim, while staying clear of screw posts.
+    lip_outer_w = inner_w + tol - lid_clearance;
+    lip_outer_d = inner_d + tol - lid_clearance;
+    lip_inner_w = lip_outer_w - lid_lip_wall*2;
+    lip_inner_d = lip_outer_d - lid_lip_wall*2;
+
+    translate([0, 0, -lid_lip_h])
+        difference() {
+            rounded_cube0(lip_outer_w, lip_outer_d, lid_lip_h, 1.0);
+            translate([0, 0, -0.1])
+                rounded_cube0(lip_inner_w, lip_inner_d, lid_lip_h + 0.2, 0.7);
+
+            // Corner reliefs so the lip doesn't interfere with screw posts.
+            for (x = [-1, 1], y = [-1, 1]) {
+                translate([x*(outer_w/2 - 5), y*(outer_d/2 - 5), lid_lip_h/2])
+                    cylinder(d=7.0, h=lid_lip_h + 0.4, center=true, $fn=24);
+            }
+        }
+}
+
 module case_lid() {
     difference() {
-        rounded_cube0(outer_w, outer_d, wall*2, 1.8);
+        union() {
+            // Thinner top cover; underside lip handles registration.
+            rounded_cube0(outer_w, outer_d, lid_top_thick, 0.8);
+            lid_locating_lip();
+        }
 
         for (x = [-1, 1], y = [-1, 1]) {
-            translate([x*(outer_w/2 - 5), y*(outer_d/2 - 5), -0.5])
+            translate([x*(outer_w/2 - 5), y*(outer_d/2 - 5), -lid_lip_h - 0.5])
-                cylinder(d=2.4, h=wall*2 + 1, center=false, $fn=20);
+                cylinder(d=2.4, h=lid_top_thick + lid_lip_h + 1, center=false, $fn=20);
         }
 
         for (x = [-outer_w/4, 0, outer_w/4]) {
-            translate([x, 0, wall*2/2])
+            translate([x, 0, lid_top_thick/2])
-                cube([8, outer_d*0.6, wall*3], center=true);
+                cube([8, outer_d*0.6, lid_top_thick*3], center=true);
         }
     }
 }
@@ -147,7 +192,7 @@ 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);
@@ -174,25 +219,21 @@ module clamp_ears() {
     }
 }
 
-module clamp_dovetail_socket() {
+module clamp_mount_plate() {
     outer_r = pole_dia/2 + clamp_thick;
-    socket_outer_w = rail_outer_w + socket_wall*2;
+    plate_y = -outer_r - mount_plate_thick/2 + 0.2;
-    socket_depth   = rail_depth + socket_wall*2;
 
-    // Solid boss on the rear of the clamp, opposite the tightening mouth.
+    // Flat plate matching the case boss. Two M3 clearance holes pass through
-    // A matching dovetail void is cut through it along Z so the case rail
+    // along Y so the clamp bolts to the case with ordinary hardware.
-    // slides in from the top/bottom with practical FDM clearance.
     difference() {
-        translate([0, -outer_r - socket_depth/2 + socket_wall, 0])
+        translate([0, plate_y, 0])
-            rounded_cube_centered(socket_outer_w, socket_depth, clamp_width, 1.2);
+            rounded_cube_centered(mount_plate_w, mount_plate_thick, mount_plate_h, mount_boss_r);
 
-        translate([0, -outer_r - 0.15, 0])
+        for (xoff = [-mount_hole_spacing/2, mount_hole_spacing/2]) {
-            dovetail_prism(
+            translate([xoff, plate_y, 0])
-                clamp_width + 1.0,
+                rotate([90, 0, 0])
-                rail_neck_w + rail_clearance,
+                    cylinder(d=mount_screw_clear, h=mount_plate_thick + 2, center=true, $fn=24);
-                rail_outer_w + rail_clearance,
+        }
-                rail_depth + 0.6
-            );
     }
 }
 
@@ -200,7 +241,7 @@ module tripod_clamp() {
     union() {
         clamp_ring_with_mouth();
         clamp_ears();
-        clamp_dovetail_socket();
+        clamp_mount_plate();
     }
 }
 
@@ -211,7 +252,7 @@ module tripod_clip() {
 
 module full_case() {
     case_body();
-    translate([0, 0, outer_h + 2]) case_lid();
+    translate([0, 0, outer_h]) case_lid();
     translate([0, outer_d/2 + pole_dia/2 + clamp_thick + 8, outer_h/2])
         rotate([90, 0, 0]) tripod_clamp();
 }