# Prototype assembly and open items

## Resolve before final assembly

1. **Inherited front-switch clamp screw access.** Two enclosed cylindrical voids are present in the original and retained front shell at X=±17, Y=-47, Z=-3.2 to -2.6 mm. Each is Ø1.7 mm × 0.6 mm deep and is enclosed by shell material. The original assembly guide calls for two M2 clamp screws, but these cavities alone do not provide an accessible pilot path. Review the screw direction, engagement, head access and remaining wall thickness in CAD before authorizing a drilling or geometry change. This package does not prescribe blind drilling through an assembled device.
2. **Actual hardware fit and switch travel.** The delivered assembled STEP contains the 17 enclosure components, not a certified hardware assembly. Vendor hardware CAD is preserved in `inputs/`. Reconstructed side-switch orientations and actuation gaps remain unqualified in this release. Use the actual plunger face and button drive nub to check alignment, rest clearance, actuation and hard stops; a whole-mesh minimum distance is insufficient.
3. **Soft-part installation and retention.** The rim and grip are valid CAD solids, but insertion strain, pull-off force, creep, fatigue and durability require physical tests with the selected elastomer/process. Confirm the flexible studs can install into the rigid carrier without tearing.
4. **Adhesive and cap stack.** The 0.10 mm films reserve nominal bond thickness. Verify bond preparation, cure, peel/shear durability, cap edge feel and button movement after bonding. Avoid adhesive squeeze-out into guides, ports and switch interfaces.

## Proposed fit-trial sequence

This is an assembly planning sequence. Confirm it against the actual hardware and baseline guide after resolving the clamp access issue.

1. Review all part IDs and process selections; fabricate fit samples for the rim interface, PTT retention studs and cap/bond stack.
2. Clean and inspect rigid shells and carriers. Verify speaker, LED, microphone, fastener and cable features before installing electronics.
3. Fit the metal-face substitutes or finished faces onto the front/volume carriers with the selected bond thickness. Fit the orange grip onto the PTT carrier. Confirm the original moving interfaces remain clear.
4. Trial-fit the lens, controls and switch clamp. The status lens retains the source press-fit interference; qualify it with the actual translucent material before forcing it into place.
5. Move the microphone hardware to the new X=0, Y=-14 port and matching internal pocket. Verify the gasket, retention, wiring route and acoustic opening with the actual microphone module.
6. Follow the original NoStack hardware arrangement for the remaining components, checking actual switch orientation, cable clearance and fasteners. The centered microphone is an intentional change to that reference arrangement.
7. Test each control through its full travel before closing the shell. Check that the new cap/grip assemblies do not bind and that switches actuate before the hard stops.
8. Close the rigid enclosure, then trial-install the flexible sleeve and recheck controls, USB access and all port openings. If insertion strain is excessive, revise the sleeve/process instead of forcing it.

The exploded STEP/GLB separates parts for identification; its offsets are not an assembly-motion simulation. No gasket sealing, ingress rating, drop rating, acoustic performance or RF performance is established by this CAD release.