# Concept 27 R2 assembly guide

Prototype engineering handoff. Geometry checks do not qualify force, material or durability.

## 1. Verify parts and processes

Use the per-part BOM and STEP in millimetres. Select material samples, cut soft stock from its free-state definition where supplied, and inspect pilots / slots. Do not print the complete assembly as one body.

## 2. Prepare front controls

Bond the pewter faces to rigid carriers and orange grip to the PTT carrier. Preserve actuation clearances. Seat the lens and trial the original press fit.

## 3. Populate front subassembly

Fit front switch and clamp before the PCB. Fit side switches in the retained cages. Install speaker gasket, ear keepers, microphone seal / seats / keeper, and horizontal LED / light coupler. Keep screws accessible before the board and battery cover them.

## 4. Prepare rear subassembly

Attach PET seat film and antenna, then its nonmetal service frame with four nylon M2x3 screws. Use the upper screw access reliefs before installing the upper battery liners. Fit rear pads and remaining liners.

## 5. Place PCB and battery

Seat the board only on the paired bare-FR4 support zones. Install the pouch in the separate upper tray; left split pads must clear its protection module. Route actual leads in the channel under capture tabs, clear of seams and moving controls.

## 6. Close and test

Bring the rear subassembly straight toward the front. Installed soft-pad shapes are geometric targets; compress real stock gradually and verify loads. Fit four M2.5x12 screws and qualify torque. Fit the flexible rim last. Check actual USB cable and every control.

## 7. Service

Remove rim before closure screws. Lift rear cover carefully for coax / leads. Remove PCB and battery for front keeper / clamp access. Remove upper battery liners before the upper antenna-frame screws. Replace damaged stock or adhesive.