$fn = 64;

// --- Parameters ---
cover_width = 80;        // Total width of the outlet cover
cover_height = 90;       // Total height of the outlet cover
cover_depth = 12;        // Thickness of the outer frame
frame_thickness = 12;    // Width of the stone arch frame

grid_bar_width = 4;      // Thickness of the portcullis bars
grid_bar_depth = 4;      // Depth of the portcullis bars
cable_gap = 25;          // Opening height at the bottom for cables

num_v_bars = 5;          // Number of vertical bars
num_h_bars = 4;          // Number of horizontal bars

// --- Modules ---

// Inner arch cutout shape used for framing and grid bounding
module inner_shape(thickness, y_bleed=0) {
    inner_w = cover_width - 2 * frame_thickness;
    straight_h = cover_height - cover_width / 2;
    
    union() {
        translate([0, -y_bleed, 0])
            cube([inner_w, straight_h + y_bleed, thickness]);
        translate([inner_w / 2, straight_h, 0])
            cylinder(d=inner_w, h=thickness);
    }
}

module portcullis_cover() {
    union() {
        // Main Frame (Stone Arch)
        difference() {
            // Outer shape
            union() {
                cube([cover_width, cover_height - cover_width/2, cover_depth]);
                translate([cover_width/2, cover_height - cover_width/2, 0])
                    cylinder(d=cover_width, h=cover_depth);
            }
            // Inner cutout (y_bleed ensures a clean cut at the bottom)
            translate([frame_thickness, 0, -1])
                inner_shape(cover_depth + 2, y_bleed=1);
        }

        // Portcullis Grid (Flush with the back for easy, support-free 3D printing)
        translate([0, 0, 0]) {
            intersection() {
                // Bounding volume to perfectly trim the grid inside the arch
                translate([frame_thickness, 0, 0])
                    inner_shape(grid_bar_depth, y_bleed=0);

                // Grid bars
                union() {
                    // Vertical bars
                    v_spacing = (cover_width - 2*frame_thickness - grid_bar_width) / (num_v_bars - 1);
                    for (i = [0 : num_v_bars - 1]) {
                        bar_x = frame_thickness + i * v_spacing;
                        translate([bar_x, cable_gap, 0])
                            cube([grid_bar_width, cover_height, grid_bar_depth]);
                    }

                    // Horizontal bars
                    h_spacing = (cover_height - cable_gap - grid_bar_width) / num_h_bars;
                    for (i = [0 : num_h_bars - 1]) {
                        bar_y = cable_gap + grid_bar_width/2 + i * h_spacing;
                        translate([frame_thickness, bar_y, 0])
                            cube([cover_width - 2*frame_thickness, grid_bar_width, grid_bar_depth]);
                    }
                }
            }

            // Spikes at the bottom of vertical bars (pointing down into the cable gap)
            v_spacing = (cover_width - 2*frame_thickness - grid_bar_width) / (num_v_bars - 1);
            for (i = [0 : num_v_bars - 1]) {
                bar_x = frame_thickness + i * v_spacing;
                translate([bar_x + grid_bar_width/2, cable_gap, grid_bar_depth/2])
                    rotate([90, 0, 0])
                    cylinder(d1=grid_bar_width, d2=0, h=min(8, cable_gap));
            }
        }
    }
}

// Render the object
portcullis_cover();