Add countersinks and recessed screw holes to extended GFCI plates

- Add 5mm diameter, 2mm deep countersinks around outer screw holes (front face)
- Make main pill-shaped screw holes recessed from back (3.5mm deep)
- Leaves 1.5mm solid wall on front face for clean appearance
- Add STL exports for all light switch plate variants

🤖 Generated with [Claude Code](https://claude.com/claude-code)

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

light-switches/gfci-paddle-switch-extended-offset.scad

@@ -35,12 +35,18 @@ screw_holes_enabled = true;
 screw_hole_height = 6.0;    // mm - vertical dimension (was diameter)
 screw_hole_width = 14.0;    // mm - horizontal dimension (250% of height)
 screw_hole_spacing = 83.3;  // mm - distance between main screw holes
+main_screw_recess_depth = 3.5;  // mm - depth from back face (Z=5), leaves solid wall on front
 
 // Outer screw holes (smaller, beyond the main holes)
 outer_screw_holes_enabled = true;
 outer_screw_hole_offset = 6.35;  // mm (0.25 inches) beyond main holes
 outer_screw_hole_diameter = 2.68;  // mm (67% of main hole diameter)
 
+// Countersink around outer screw holes (front face)
+countersink_enabled = true;
+countersink_diameter = 5.0;       // mm - total diameter of recess
+countersink_depth = 2.0;          // mm - depth of recess into front face
+
 /* [Resolution] */
 $fn = 64;
 
@@ -100,25 +106,42 @@ module paddle_opening_3d() {
 
 module screw_holes() {
     if (screw_holes_enabled) {
+        // Main screw holes: recessed from back face (positive Z), solid wall on front
+        main_screw_start_z = plate_thickness - main_screw_recess_depth;
+
         // Top main screw hole (pill-shaped, horizontal)
-        translate([0, screw_hole_spacing/2, -0.1])
-            linear_extrude(height = plate_thickness + 0.2)
+        translate([0, screw_hole_spacing/2, main_screw_start_z])
+            linear_extrude(height = main_screw_recess_depth + 0.1)
                 rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
 
         // Bottom main screw hole (pill-shaped, horizontal)
-        translate([0, -screw_hole_spacing/2, -0.1])
-            linear_extrude(height = plate_thickness + 0.2)
+        translate([0, -screw_hole_spacing/2, main_screw_start_z])
+            linear_extrude(height = main_screw_recess_depth + 0.1)
                 rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
     }
 
     if (outer_screw_holes_enabled) {
         // Top outer screw hole (above top main hole)
-        translate([0, screw_hole_spacing/2 + outer_screw_hole_offset, -0.1])
+        translate([0, screw_hole_spacing/2 + outer_screw_hole_offset, 0]) {
+            // Through-hole
+            translate([0, 0, -0.1])
                 cylinder(h = plate_thickness + 0.2, d = outer_screw_hole_diameter);
+            // Countersink on front face
+            if (countersink_enabled)
+                translate([0, 0, -0.1])
+                    cylinder(h = countersink_depth + 0.1, d = countersink_diameter);
+        }
 
         // Bottom outer screw hole (below bottom main hole)
-        translate([0, -screw_hole_spacing/2 - outer_screw_hole_offset, -0.1])
+        translate([0, -screw_hole_spacing/2 - outer_screw_hole_offset, 0]) {
+            // Through-hole
+            translate([0, 0, -0.1])
                 cylinder(h = plate_thickness + 0.2, d = outer_screw_hole_diameter);
+            // Countersink on front face
+            if (countersink_enabled)
+                translate([0, 0, -0.1])
+                    cylinder(h = countersink_depth + 0.1, d = countersink_diameter);
+        }
     }
 }
 

light-switches/gfci-paddle-switch-extended.scad

@@ -32,11 +32,17 @@ screw_holes_enabled = true;
 screw_hole_height = 6.0;    // mm - vertical dimension (was diameter)
 screw_hole_width = 14.0;    // mm - horizontal dimension (250% of height)
 screw_hole_spacing = 83.3;  // mm - distance between main screw holes
+main_screw_recess_depth = 3.5;  // mm - depth from back face (Z=5), leaves solid wall on front
 
 // Outer screw holes (smaller, beyond the main holes)
 outer_screw_holes_enabled = true;
 outer_screw_hole_offset = 6.35;  // mm (0.25 inches) beyond main holes
-outer_screw_hole_diameter = 2.68;  // mm (67% of main hole diameter)
+outer_screw_hole_diameter = 3.175;  // mm (67% of main hole diameter)
+
+// Countersink around outer screw holes (front face)
+countersink_enabled = true;
+countersink_diameter = 5.0;       // mm - total diameter of recess
+countersink_depth = 2.0;          // mm - depth of recess into front face
 
 /* [Resolution] */
 $fn = 64;
@@ -94,25 +100,42 @@ module paddle_opening_3d() {
 
 module screw_holes() {
     if (screw_holes_enabled) {
+        // Main screw holes: recessed from back face (positive Z), solid wall on front
+        main_screw_start_z = plate_thickness - main_screw_recess_depth;
+
         // Top main screw hole (pill-shaped, horizontal)
-        translate([0, screw_hole_spacing/2, -0.1])
-            linear_extrude(height = plate_thickness + 0.2)
+        translate([0, screw_hole_spacing/2, main_screw_start_z])
+            linear_extrude(height = main_screw_recess_depth + 0.1)
                 rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
 
         // Bottom main screw hole (pill-shaped, horizontal)
-        translate([0, -screw_hole_spacing/2, -0.1])
-            linear_extrude(height = plate_thickness + 0.2)
+        translate([0, -screw_hole_spacing/2, main_screw_start_z])
+            linear_extrude(height = main_screw_recess_depth + 0.1)
                 rect([screw_hole_width, screw_hole_height], rounding=screw_hole_height/2);
     }
 
     if (outer_screw_holes_enabled) {
         // Top outer screw hole (above top main hole)
-        translate([0, screw_hole_spacing/2 + outer_screw_hole_offset, -0.1])
+        translate([0, screw_hole_spacing/2 + outer_screw_hole_offset, 0]) {
+            // Through-hole
+            translate([0, 0, -0.1])
                 cylinder(h = plate_thickness + 0.2, d = outer_screw_hole_diameter);
+            // Countersink on front face
+            if (countersink_enabled)
+                translate([0, 0, -0.1])
+                    cylinder(h = countersink_depth + 0.1, d = countersink_diameter);
+        }
 
         // Bottom outer screw hole (below bottom main hole)
-        translate([0, -screw_hole_spacing/2 - outer_screw_hole_offset, -0.1])
+        translate([0, -screw_hole_spacing/2 - outer_screw_hole_offset, 0]) {
+            // Through-hole
+            translate([0, 0, -0.1])
                 cylinder(h = plate_thickness + 0.2, d = outer_screw_hole_diameter);
+            // Countersink on front face
+            if (countersink_enabled)
+                translate([0, 0, -0.1])
+                    cylinder(h = countersink_depth + 0.1, d = countersink_diameter);
+        }
     }
 }