# J9 control harness — R3.6 original exterior

This harness connects the fixed J9 PCB header to the four retained switches. It adds two wire supports inside P01, local wire/terminal clearance, nine wire pieces and one supported insulated common junction. It adds no screw or loose printed keeper. The original exterior, PCB position, battery factory leads and battery plug are retained.

**Release remains conditional on the unpowered assembly, electrical continuity and material/process checks below.** The CAD establishes mechanical routing around nominal switch models; it does not establish an electrical pinout or certify physical durability.

## Connector and wire

Use one JST PHR-5 housing and five SPH-002T-P0.5S crimp contacts. The manufacturer's contact table permits AWG 30–24 and insulation diameter 0.8–1.5 mm. Confirm the wire, plating, contact and approved crimp tooling together. The CAD housing is a conservative catalog external gauge, 6.85 × 11.8 × 4.5 mm; latch details and conductor-exit positions need a received-part check. [JST PH manufacturer drawing](https://www.jst-mfg.com/product/pdf/eng/ePH.pdf)

The routing uses stranded 26 AWG wire with **measured insulation diameter no greater than 1.05 mm** and a **3 mm static bend radius**. A dimensionally suitable manufacturer example is Tonichi Kyosan UL1061 SPE-34B, 7/0.16 conductor, approximately 0.98 mm finished diameter. That approximate diameter is not a maximum tolerance or a qualified purchased lot. R3 is this design's assumption, not a published minimum bend radius. Verify both on the selected wire. [Tonichi Kyosan UL1061 table](https://www.tonichi-kyosan.co.jp/product/equipment_ul1061/index.html)

## Wire schedule

All lengths are millimetres. The modeled length runs between the defined CAD endpoints. Initial cuts include at least 20 mm for termination and fitting; the short pigtail also includes joint-insertion allowance. Trim after a trial fit. **Do not store the extra cutting allowance as an unmodeled loop inside the case.**

The pin numbers below identify geometric rows in the five-position connector. Confirm their electrical nets from the actual PCB/schematic before terminating the housing.

| CAD wire | Intended connection, subject to continuity check | Modeled path | Initial stock cut |
|---|---|---:|---:|
| J9 pin 1 | PTT signal | 130.29 | 155 |
| J9 pin 2 | Upper-volume signal | 57.27 | 80 |
| J9 pin 3 | Lower-volume signal | 52.24 | 75 |
| J9 pin 4 | Play/front-button signal | 67.28 | 90 |
| J9 pin 5 | Lower-volume common | 65.04 | 90 |
| Common link 1 | Lower-volume common to upper-volume junction | 33.19 | 55 |
| Common link 2 | Upper-volume junction to PTT common | 46.98 | 70 |
| Common link 3 | PTT common to play common | 85.53 | 110 |
| Upper-volume short pigtail | Junction to upper-volume common terminal | 7.49 | 30 |

The proposed common-return chain uses separate same-contact legs at the lower-volume and PTT switches, with one wire per used leg. Check those leg pairs by continuity; the inherited switch solids are explicitly nominal, non-OEM references. If the actual switch contact arrangement differs, revise the harness instead of forcing this connection scheme.

## Insulation, supports and stock

Stock thicknesses are **installed total thickness, including adhesive**. Use electrically insulating, nonabrasive materials. The stock models are purchasing/placement references and must not be printed as rigid parts.

| Item | Quantity and dimensions | Placement / purpose |
|---|---|---|
| Terminal insulation | 10 joint envelopes, maximum Ø1.5 × 2.0–3.2 long, according to the named CAD joints | Fully covers each soldered leg and exposed conductor. Qualify the actual sleeve and solder process within these envelopes. |
| Common-junction insulation | 1, maximum Ø2.4 × 6 | Upper-volume junction at X17…23, Y23.4, Z−11.25; contains the two common links and short pigtail. |
| PTT retaining tape | 1, 5 × 3 × 0.10 installed | Rear of the P01 support at X−25.5…−20.5, Y−15.5…−12.5. Retains the lower return wire in its open groove. |
| Junction silicone facing | 1, 3.5 × 0.8 × 0.30 installed | X19…22.5, Y23.0…23.8, Z−10.05…−9.75. Cushions the insulated junction. |
| Junction polyester loop | 1, initial 2.5 × 40 × 0.10 stock; self-bond overlap at least 10 | Threads through the 3 × 1.2 through-slot in the P01 support and wraps the insulated junction. Snug without pulling the solder joints. |

The PTT support has an upper nominal Ø1.65 passage and a rear-open lower channel, each locally matched to the actual wire route with 0.30 mm radial allowance. Feed the upper wire **before final terminal soldering**. The support's side ligaments are 1.675 mm. The rear tape lands total approximately 10.05 mm²; their actual adhesion must be tested.

The common-junction support has a front-shell root at X25…29.5, Y14.5…18.5 and a shelf at X17…29.5, Y18.5…24.8. It deliberately merges with the retained PCB-support backing; it does not bear on the PCB itself. The shelf is 2.15 mm thick, with a 1.85 mm local pad seat and a 3 × 1.2 mm through-slot for the loop. Its wire exit is relieved. The loop is centred at X20.5, clears the battery toe by approximately 0.408 mm and the intact factory leads by at least 0.35 mm in nominal CAD. The short pigtail has approximately 0.183 mm clearance to the loop. The actual folded tape must fit within its modeled envelope; hold release if bunching touches or loads the pigtail.

The lower play lead also passes beside the J8 harness saddle. Use the final matched saddle and J9 wire relief together. Do not substitute the earlier rectangular saddle. The play lead clears the final K02 volume keeper by 0.446 mm nominally and uses existing P04 access; no additional P04 cut is required for this route.

## Assembly and service sequence

1. Confirm the actual switch contact pairs and J9 PCB nets with power disconnected. Label the conductors and record the mapping.
2. Print and qualify QJ01/QJ02 with the intended shell process, orientation and material. Clean the passages without enlarging them arbitrarily.
3. Lay the harness into P01 while the PCB and switches remain accessible. Feed the PTT signal through the upper support before its final terminal soldering. Keep every connector body accessible for disconnection.
4. Form and inspect the ten insulated terminal joints and the small common junction. Keep common link 1 and the junction loop free while fastening K01/K02: the final dressed link crosses K01 screw 1 and K02 screw 2 driver paths. After both volume captures are fastened, lay the flexible link into its final route, seat the junction on its silicone facing and close the tape loop. Fit the replaceable PTT return tape. Do not tighten tape by pulling a wire or switch leg.
5. Crimp and insert the verified J9 contacts, complete final dressing after the affected captures are fastened, then check every signal and common connection for continuity and unintended shorts.
6. Trial-close the unpowered case while observing the wires. Hold release if a wire moves onto the pouch, control slider, screw, sharp edge or shell seam, or if a connector is pulled sideways.
7. For service, remove F01 first, then support the PCB and front assembly together while removing the rear shell. Before accessing K01/K02, release the common-junction loop and move only the flexible common-link span clear of the driver, without pulling its soldered switch terminals. Unplug PHR-5 by its housing before lifting the PCB. Replace removed tape/loop. Full front-shell replacement may require contact depinning or solder service because the PTT signal passes through a closed support passage.

No opening angle, stored service loop or slack length has been physically demonstrated. The first article must prove the opening/disconnection sequence without tension, scraping or pinching. The extra wire in the initial cut schedule is not a promise of installed service slack.

## First-article gates

- Confirm connector latch/exit geometry, switch leg positions, sleeve dimensions and actual wire diameter. Record the verified electrical mapping.
- Print QJ01 (PTT support) and QJ02 (junction shelf together with its retained PCB backing). Their supplied STLs are watertight, consistently wound single components, with valid one-solid STEP sources.
- With the actual wire, tape and facing, check insertion without force; then apply a controlled **5 N retention screen to the coupon support/retained harness**, avoiding direct load on unqualified electrical joints. Complete **10 assembly/service cycles**. Hold release for cracking, peeling, looseness or insulation damage.
- Verify solder/crimp workmanship, insulation coverage, continuity and switch function. No bare conductor may bridge to another terminal, the PCB or a screw.
- Demonstrate complete unpowered assembly and service access. Confirm the final combined CAD/native exports preserve all exterior and mating surfaces.

The 5 N load and 10 cycles are engineering screening targets, not a manufacturer rating, drop test or life certification. The structural calculations use hypothetical effective modulus 1000 MPa and allowable stress 8 MPa; actual print anisotropy, notches, creep and adhesive performance require qualification.

## Rebuild / audit

The integration allowlist and exact hashes are in `J9_FINAL_INTEGRATION_MANIFEST.json`. Rebuild from the exact pre-J9 mechanical/fixture baseline, apply its wire cuts and two support additions, then apply the final fixture corrections. Do not add this shelf on top of the superseded support. The correction manifest names the archived prior files. Keep the complete final fixture/J9 operation sequence for rebuilds.

Exact centerlines, shell-cut bounds/volumes, source hashes, clearance results and risks are recorded in `j9_route_geometry.json`, `j9_shell_mask_audit.json`, `j9_final_verification.json`, `j9_coupon_mesh_checks.json` and `risk_register_j9.json`. Trial shells and superseded central-splice candidates are excluded from the manufacturing assembly.