Case: two more body screws near the front

The base only screwed to the body at the back. New bosses in the side walls sit just behind the display, clear of the bezel's slide-in path; the base rim gets a gap around them and the feet part now has 6 feet.

Co-Authored-By: Claude Opus 5.5 <noreply@anthropic.com>

case/vfd-case.scad

@@ -7,11 +7,11 @@
 //
 // Assembly:
 //   1. Melt M3 heat-set inserts into: 4 display bosses + 2 feet on the bezel,
-//      2 rear corner bosses in the body, 4 board standoffs on the base.
+//      2 rear corner + 2 front side bosses in the body, 4 board standoffs on the base.
 //   2. Bolt the display to the bezel from behind (4x M3x6).
 //   3. Screw the D1 board onto the base (4x M3x6).
 //   4. Slide the bezel (with display) up into the body's side grooves from below.
-//   5. Wire up, put the body on the base and screw it together from below (4x M3x8).
+//   5. Wire up, put the body on the base and screw it together from below (6x M3x8).
 //
 // Render one part:  openscad -D 'part="body"' -o body.stl vfd-case.scad
 // Parts: "assembly" (preview with dummy display + board), "body", "bezel", "base",
@@ -107,9 +107,17 @@ foot_n = n_bezel_in + 6;                              // insert axis in the beze
 foot_y = foot_n / cos(tilt);
 foot_xs = [inner_w * 0.25, inner_w * 0.75];
 rear_boss = 9;                                        // rear corner boss block size
+boss_h = 10;                                          // body boss height before the chamfer
 rear_screws = [[rear_boss / 2, depth - wall - rear_boss / 2],
                [inner_w - rear_boss / 2, depth - wall - rear_boss / 2]];
-base_screws = concat([for (x = foot_xs) [x, foot_y]], rear_screws);
+// front side bosses: far enough back that the display's back stays clear while
+// the bezel slides in along the panel
+n_disp_back = n_pcb + pcb_t + disp_back;
+front_boss_y = ceil((n_disp_back + 2 + (boss_h + rear_boss) * sin(tilt)) / cos(tilt));
+front_screws = [[rear_boss / 2, front_boss_y + rear_boss / 2],
+                [inner_w - rear_boss / 2, front_boss_y + rear_boss / 2]];
+body_screws = concat(front_screws, rear_screws);
+base_screws = concat([for (x = foot_xs) [x, foot_y]], body_screws);
 
 echo(str("Outer size: ", outer_w, " x ", depth, " x ", height + base_t, " mm (W x D x H)"));
 
@@ -151,19 +159,23 @@ module body() {
         for (i = [0 : 3]) translate([inner_w / 2, depth - wall - 14 - i * 8, height - wall / 2])
             linear_extrude(wall + 2, center = true) rrect(inner_w - 50, 3, 1.4);
     }
-    // rear corner bosses for the base screws, chamfered up into the walls
-    for (p = rear_screws) {
-        x0 = p[0] < inner_w / 2 ? 0 : inner_w - rear_boss;
-        xw = p[0] < inner_w / 2 ? 0 : inner_w - 0.01;
-        difference() {
-            hull() {
-                translate([x0, depth - wall - rear_boss, 0]) cube([rear_boss, rear_boss, 10]);
-                translate([xw, depth - wall - 0.01, 0]) cube([0.01, 0.01, 10 + rear_boss]);
-                translate([x0, depth - wall - 0.01, 0]) cube([rear_boss, 0.01, 10 + rear_boss]);
-                translate([xw, depth - wall - rear_boss, 0]) cube([0.01, rear_boss, 10 + rear_boss]);
-            }
-            translate([p[0], p[1], -1]) cylinder(d = insert_d, h = insert_depth + 1);
+    // bosses for the base screws, chamfered up into the walls
+    for (p = rear_screws) body_boss(p, true);
+    for (p = front_screws) body_boss(p, false);
+}
+
+// rear: in the corner, chamfered into the side and back walls; front: side wall only
+module body_boss(p, rear) {
+    x0 = p[0] < inner_w / 2 ? 0 : inner_w - rear_boss;
+    xw = p[0] < inner_w / 2 ? 0 : inner_w - 0.01;
+    y0 = p[1] - rear_boss / 2;
+    difference() {
+        hull() {
+            translate([x0, y0, 0]) cube([rear_boss, rear_boss, boss_h]);
+            translate([xw, y0, 0]) cube([0.01, rear_boss, boss_h + rear_boss]);
+            if (rear) translate([x0, y0 + rear_boss - 0.01, 0]) cube([rear_boss, 0.01, boss_h + rear_boss]);
         }
+        translate([p[0], p[1], -1]) cylinder(d = insert_d, h = insert_depth + 1);
     }
 }
 
@@ -210,8 +222,12 @@ module base() {
             translate([-wall, 0, -base_t]) cube([outer_w, depth, base_t]);
             // locating rim inside the side and back walls (stops short of the bezel and bosses)
             rim_y0 = 20;
-            for (x = [clr, inner_w - clr - 1.6])
-                translate([x, rim_y0, -0.01]) cube([1.6, depth - wall - rear_boss - clr - rim_y0, 2]);
+            difference() {
+                for (x = [clr, inner_w - clr - 1.6])
+                    translate([x, rim_y0, -0.01]) cube([1.6, depth - wall - rear_boss - clr - rim_y0, 2]);
+                for (p = front_screws) translate([p[0], p[1], 1])
+                    cube([rear_boss + 2 * clr, rear_boss + 2 * clr, 4], center = true);
+            }
             translate([rear_boss + clr, depth - wall - clr - 1.6, -0.01])
                 cube([inner_w - 2 * (rear_boss + clr), 1.6, 2]);
             // board standoffs
@@ -314,7 +330,7 @@ if (part == "assembly") {
 } else if (part == "bezel") {
     translate([0, 0, -lip]) multmatrix(M) bezel();                 // front face on the bed
 } else if (part == "feet") {
-    for (i = [0 : len(base_screws) - 1])                         // 4 feet, flat side down
+    for (i = [0 : len(base_screws) - 1])                         // 6 feet, flat side down
         translate([i * (foot_d + 5), 0, foot_h]) foot();
 } else if (part == "base") {
     translate([0, 0, base_t]) base();