# R3.6 antenna, connectors and harness

## Scope and evidence

This subsystem uses the supplied original R3.4 assembly, SHA-256 `8225c7b494a1dba6cc91e7251539007268a1fd52d0bb531302c7296d3b7adaa0`. It adds no enclosure depth and moves no PCB, header, USB opening or control. Internal antenna placement and retainers change. Original battery factory leads, protection/tab covering and PHR-2 plug remain intact.

The STEP cable bodies are nominal installation routes, not cable-manufacturing drawings. Catalog connector gauges reserve the complete outside envelope without the internal mating cavity. Their overlap with the correct PCB header is intentional. All original PCB headers stay in the assembly; no leaf of the PCB is removed to conceal a gauge overlap. Solid validity and nominal clearance do not prove contact compatibility, crimp quality, RF performance or strength.

## Connection schedule

| Interface | Mechanical implementation | Assembly/electrical qualification |
|---|---|---|
| J2 battery | 2-circuit JST CK socket on unchanged PH board header, selected AWG 26 UL1061 7-strand tin-plated wire, maximum OD 1.05. Two-wire passive carrier and added B2B-PH header receive the intact factory PHR-2. | Check CK wire-exit variant and cavity numbering, factory plug fit, polarity, continuity, peak current, voltage drop and insulation. The carrier is passive; it changes no circuit or PCB header. |
| J3 microphone | 5-circuit CK on unchanged PH header, UL1061 AWG 28 maximum OD 1.05; five routes terminate at the existing microphone terminal row. | Verify BCLK/WS/DATA/power/ground pin map and SEL treatment from the electrical schematic. Do not use the geometric row order as a wiring instruction. |
| J8 LED | PHR-4 housing with four matching PH crimp contacts, UL1061 AWG 28 maximum OD 1.05. Existing formed LED legs and LED body stay in place. | Verify PH crimp selection, RGB/common mapping and insulated solder joints. Each terminal joint must remain within Ø1.15 mm including qualified thin insulation; original lead pitch 1.27 mm leaves 0.12 mm nominal separation. Measure finished joints; do not fit oversized sleeves by forcing adjacent leads. Preserve the existing lead bend away from the lens. |
| J9 controls | PHR-5 and five PH contacts on unchanged side-entry header. Four signal routes plus the final common-return daisy chain. | Separate J9 manifest and tests own these paths. Check GPIO/net mapping and electrical continuity; CAD has no firmware validation. |
| J10 speaker | 2-circuit CK with selected AWG 26 UL1061 maximum OD 1.05. Two staggered insulated lap-splice envelopes connect to shortened factory speaker leads. | Speaker factory UL1007 insulation is not assumed compatible with CK IDC. Actual factory wire exit and OD must fit the reserved path. Two sleeve envelopes are maximum Ø3.2 × 8 mm; both conductors enter the same sleeve end. |
| J5 cellular RF | Original Taoglas 150 mm Ø1.37 coax and fixed original MHF/U.FL-compatible plug; explicit 150 mm centerline and two formed straps on unbonded silicone half-saddles. | Feed point and R5 bend are design assumptions. Confirm the factory coax exit, actual connector orientation and cable bend behavior. Connect to CELL_RF J5. |
| J1/J11/J12/J6 | Existing optional/service/spare/GNSS board interfaces remain at original locations. | Not part of the installed harness; no plug or wire is silently added. |

For custom new wires, begin with the modeled centerline length plus 20 mm for termination and trial dressing, then trim to the actual termination depths and measured route before final crimp/IDC/solder operations. Do not force unmodeled excess into the case. Keep small service slack within the reserved bends. The factory battery's two 100 mm curves preserve the old CAD length assumption; actual available free length, insulation OD, tab exit and plug position must be measured. They are not permission to cut, extend, resolder or retape the battery pouch assembly.

### Connector facts and BOM

Use two normal/reverse-exit **02CK-6H-P / 02CK-6H-PC** sockets for J2/J10 and one **05CK-6H-P / 05CK-6H-PC** for J3 only after the cable-side exit and pin 1 are confirmed. JST specifies CK mating with PH headers, mounted height 6.9 mm, body depth 4.2 mm, widths 6/12 mm, approved AWG 26/28 wire, OD 0.75–1.05 mm. The wire-center exit Z in this design is an assumption, not a separately dimensioned catalog datum. The claimed 2 A rating is for AWG 26; actual battery load still needs review. See [JST CK catalog](https://www.jst-mfg.com/product/pdf/eng/eCK.pdf).

Retain original PCB headers. Add one **B2B-PH-K-S(LF)(SN)** on the passive two-net FR4 carrier; its reference is a copy of the actual original J2 header geometry. Add one PHR-4 and one PHR-5 with nine total matching contacts for J8/J9; existing battery plug and contacts are reused intact. Verify contact/wire compatibility with the [JST PH catalog](https://www.jst-mfg.com/product/pdf/eng/ePH.pdf). The selected speaker remains [CMS-40504N-L152](https://www.sameskydevices.com/product/resource/cms-40504n-l152.pdf); the source's 152±5 mm leads may be shortened to terminate on the defined splices. Speaker wire exit was absent from the original model, so its starting coordinates remain a hardware inspection gate.

## Adapter assembly and load path

The 8 × 6 × 1 mm passive FR4 carrier is captured by four 0.25 mm installed silicone edge pads in the revised cradle and K03 cover. Thread the two manufactured bare pigtail ends through the loose final K03 passage before soldering or fitting the finished termination insulation. Preassemble the wired carrier, header, insulation, pads, grommet and final K03 outside the shell. Insert the complete module from the open rear with its flexible pigtail undressed and the battery plug disconnected; do not slide the separate cover past fixed solder joints. The factory battery plug later mates from +Y. The final two M2 × 6 pan screws install from the open rear, before the main PCB/module. Axes are X15.6/28.1, Y−6.05; head envelope Ø4 × 1.6 mm. The controlled Ø1.7 mm pilots provide 4.0 mm nominal material engagement and 0.60 mm point clearance. A 1.0 mm tip/runout reserve leaves a 3.0 mm design full-thread allowance; establish actual useful threads and tightening torque on QF01B.

The corrected carrier drills are Ø0.95 ±0.03 mm at X21/23, Z−6.7, matching the imported header tails. Use the fabricated two-pad carrier and separate fitted termination insulation from the carrier drawing; do not use the earlier Z−7.3 holes or old solder allowance. Front backing is 2.8 × 3.0 mm, with 3.6 mm² contact under each front pad. Final local pilot ligaments are 1.20548 mm left and 0.96161 mm right to the wire channels, and 0.95 mm on the right carrier side. Use controlled tapping and the exact coupon; do not force self-tapping screws into these local sections.

K03 now has a 6.0 mm-deep grommet crossbar with separate lower/upper rail minima of 2.025/2.14 mm. Its rounded front opening clears the corrected termination insulation by 0.36 mm. Use final cover hash `580eec6470b4…`, with QF01B as the unchanged receiver test base.

The outgoing CK pigtail passes through the split silicone grommet in K03 at X21/23, Y−12.3…−10.3, Z−7.3. The grommet acts on insulated wire outside the solder allowance. The cover and carrier capture take mating/pull loads into the shell, rather than asking the solder joints to hold the cable. Qualify the silicone grip and carrier pad compression on QF01B. Candidate free silicone pads 0.30 mm compress to 0.25 mm; candidate grommet free outside 6.0 × 2.8 mm fits installed 5.8 × 2.6 mm, with a measured wire-grip bore selected by coupon. No elastic material law is assumed from this geometry.

## Antenna and frame changes

P15/P16 replace the original narrow frame/bridge arrangements with broad 2.2 mm clamp plates. P15 main cross section is 9 × 2.2 mm; P16 is 10 × 2.2 mm. Local underside relief over the original supports leaves 1.2 mm seats; minimum radial stock at aØ2.3 hole is 1.85 mm for P15 and 2.05 mm for P16. The original four M2 × 3 **nylon** screws remain at X±14, Y−32/64. Do not substitute metal screws. Their nominal engagement is 1.8 mm with 0.62 mm tip clearance to the new pilot floors.

A rounded 22.5 × 98 mm rear bed, X±11.25, Y−35.5…62.5, is recessed toZ−22.10. The nominal broad rear skin is 1.90 mm, versus 2.20 mm originally; pilot floors locally leave 1.25 mm axial skin. The stack is 0.05 mm adhesive, 0.10 mm PET dielectric carrier, unchanged 0.20 mm antenna flex, and four 5 × 4 × 0.42 mm installed end pads. Use stock of measured installed thickness; do not stack the original thicker carrier or old soft stops with the replacements.

A simple 5 N, 28 mm simply supported span calculation gives 4.82 MPa for P15 and 4.34 MPa for P16. It assumes a homogeneous isotropic material and does not model print layers, notch effects, fastener creep or foam preload. The hypothetical 8 MPa allowable/E = 1000 MPa comparison is a screening assumption, not a material rating. QF02 and actual P15/P16 must be printed in the intended production process and screened physically.

### RF limit retained explicitly

The antenna flex front face isZ−21.75. The maximum battery body's rear face isZ−16.60, giving 5.15 mm nominal planar separation where their XY footprints overlap. The PCB rear plane gives 7.4485 mm nominal plane separation; conductive components can be closer than that plane. Both are below Taoglas's minimum 10 mm metal recommendation. The catalog housing gauges are plastic envelopes and cannot prove a metal keepout. No mechanical fit claim establishes RF performance. Antenna efficiency, matching and radiated performance require actual-device qualification. See the [Taoglas FXUB63.07.0150C datasheet](https://www.taoglas.com/datasheets/FXUB63.07.0150C.pdf).

## Wire channels and retention

Shell relief follows each actual nominal wire plus 0.40 mm radial allowance. Apply individual ordered masks with non-destructive Boolean operations and verify full-shell volume and one-solid continuity after every operation. Do not subtract an un-unioned compound of overlapping cable solids. The broad microphone window joins adjacent wire channels deliberately, removing thin fins while retaining at least 6.3 mm nominal front web to the broad inner skin. Open channels in the old battery-support material avoid leaving narrow plastic roofs.

The microphone bundle bears on the final 6.0 × 10.5 × 0.25 mm installed silicone facing, ending at Y−19.5, and is retained by the unchanged formed polyester strap. Its trimmed edge clears the strap ramp by 0.121268 mm while supporting all five wires. Use QF03 with this trimmed stock; see [Microphone Facing Final Correction](Microphone_Facing_Final_Correction.md). The separate J8 saddle has a rear-open corner for the final J9 play wire. Its new end-wrap strap bonds to the vertical end face and both horizontal lands, providing 26.3175 mm² nominal contact. The corrected saddle and strap clear that wire by 0.5081 mm and 0.3711 mm. Use QF04B; the earlier QF04 and flat J8 strap are superseded.

The coax uses two formed 4 mm-wide polyester straps bonded to the existing curved printed lands, with unbonded silicone half-saddles beneath the cable. No chemical bond to the FEP jacket is credited. The earlier RTV tacks and flat coax tape contours are excluded. Use QF05 and the [final corrections](Fixture_Final_Corrections.md) to qualify grip without cable damage.

The final shortened speaker lead 2 passes behind the PTT wiring with its local segment at Z = −8.9 mm. Its start and splice endpoint remain unchanged. Splice 1 keeps its complete Ø3.2 × 8 mm insulation reserve and moves 0.30 mm forward. Never trim insulation to clear a neighboring wire. The battery factory leads, plug and protection remain intact.

Retain the adapter wire grip and support LED/speaker joints without pulling component legs. A wire must not cross a moving control, screw pilot, seam or battery bearing face. Exact final routes and their clearance results come from the combined handoff verification; this text does not imply that all physical dressing and service conditions have been tested.

## Process and qualification

QF01B/QF02/QF03/QF04B/QF05 are standalone printable test bases. Use actual K03/P15/P16 as the mating coupons. The coupon JSON records dimensions and test setup. For filament printing, place the main bending spans/arms in the strong print plane and keep support scars away from wire grooves, seats and mating faces. SLS/MJF and tough resin still need pilot/clearance/impact screening with their actual material and post-processing. Generic brittle display resin is not assigned a universal strength or life here.

Required physical checks remain: measure the received parts; confirm CK/PH mating and wire-center exit; confirm battery tab/free-lead geometry; test the passive adapter and net map electrically; fit the inert maximum battery gauge; verify clearance throughout button travel; qualify wire bend/dressing and pull restraint; 10 assembly/service cycles and 1000 control actuations; inspect for pinching, rubbing, stripped threads and permanent set. No such physical tests were performed by this CAD work.

## Coax retention material and inspection

Use the selected mechanical strap and unbonded saddle described in [Fixture Final Corrections](Fixture_Final_Corrections.md). Candidate 3M 1350F-1 polyester/acrylic tape is 0.064 mm nominal within the 0.10 mm installation envelope. Qualify adhesion to the actual printed finish and cable grip on QF05. Do not install DOWSIL 3145 or any other RTV tack as the selected coax restraint. Keep the RF feed and plug unbonded; no factory jacket abrasion or chemical treatment is assumed.

A primary wire-family example is [Tonichi Kyosan UL1061, SPE-34B](https://www.tonichi-kyosan.co.jp/product/equipment_ul1061/index.html): AWG 26 7/0.16 with approximate finished OD 0.98 mm, or AWG 28 7/0.127 withOD 0.88 mm. The published diameters are approximate. Verify the supplied lot stays within the modeledOD 1.05 maximum and the selected JST contact accepts its conductor/insulation; R3 remains a static-routing assumption requiring actual bend inspection. No received wire lot has been qualified.

The paired factory battery risers use the final inward route. See [the inward-riser correction](Fixture_Final_Corrections.md#inward-battery-lead-risers-and-preserved-exterior) for the original-exterior and keeper-port checks. Preserve both intact factory wires.

## Final adapter update

Use [Adapter Final Seat and Fasteners](Adapter_Final_Seat_and_Fasteners.md). The selected mechanism uses rear-access M2 × 6 screws and QF01B, the corrected carrier drill row, and the CK2 lane that preserves the receiver wall. Earlier Y-axis adapter dimensions are superseded.

## Final PTT fixed rear pad

Use the trimmed 5.2 × 9.0 × 0.50 mm installed stock, ending at outboard X−36.7. The 0.50 mm free-edge trim retains all measured shell, cradle and switch bearing areas. The final full-reference PTT rerun clears the moving assembly with a 0.26250 mm continuous-clearance lower bound and eight clear unblocked midstroke rocking probes; all six simultaneous control-group pairs clear. See [Final Control Integration Review](FINAL_CONTROL_INTEGRATION_REVIEW.md). Physical operation remains a separate qualification requirement. Keep adhesive inside the cut perimeter and verify free electrical release after case tightening. See [PTT rear pad correction](PTT_REAR_PAD_STOCK_CORRECTION.md).