# Annotated component review — R3.6

This review covers all **25 original part identities and three added retainers: K01, K02 and K03**. It explains the internal changes, the reasons for retaining some parts, and the physical checks required before the design is qualified for use. The supplied R3.4 handoff is the design baseline. The original external case geometry, visible controls, openings and seam remain the protected design surfaces.

The evidence establishes nominal CAD fit, intended load paths and specific analytical screens. It does **not** establish that every print material, orientation or machine profile will survive assembly or use. A completed CAD check and a completed physical test are separate results. Record physical results in the [qualification log](Physical_Qualification_Log.csv).

## How to read the evidence

The tables link to individual entries in the [feature risk register](Feature_Risk_Register.md). Its source records contain the measured feature, failure mechanism, treatment and remaining test. The underlying [component disposition ledger](../Verification/component_dispositions.json) accounts for the 28 part identities. Hardware, optics, flexible material, films and wires are separate items; the count is not an instruction to print every item in one rigid material.

Evidence in `Verification/` is grouped by subsystem. A subsystem trial is useful evidence for that feature, but its status or hash may precede final integration. Use the final [integrated manifest](../Verification/integrated/current_manifest.json) and its matching checks to identify the actual combined parts. Historical failed trials and rejected Boolean comparisons do not constitute a passing result.

## Shells and load-bearing internal features

| Part | Disposition and reason | Evidence and physical gate |
|---|---|---|
| **P01 — Front shell** | Revised internally. Broader closure and PCB roots, shell-supported play and PTT stops, supported control receivers, battery screw-head reliefs, adapter support and a speaker-tab pocket address assembly force and concentrated loads. | [PA-01][risk-PA-01], [PA-04][risk-PA-04], [PCB-01][risk-PCB-01], [CTRL_RECEIVERS][risk-CTRL_RECEIVERS]. Both halves must seat by hand before tightening; inspect roots and thin local backed regions after servicing. |
| **P02 — Rear shell** | Revised internally. An open battery cradle replaces the restrictive fit. Broad volume-guide bases, PCB backing, closure bearing stock, antenna support and rounded wire clearances distribute loads into the shell. | [BAT01][risk-BAT01], [PA-03][risk-PA-03], [PCB-04][risk-PCB-04]. Qualify the actual battery, wires and flexible rim together; do not use screws to draw an obstructed assembly closed. |

### All eight original PCB support roots, plus three new pads

Four original front/rear contact pairs remain at their measured positions: **(−27, −33.7), (−27, 10.2), (27, 8) and (27, 17) mm**. Each pair has one support on P01 and one on P02. **All eight roots receive backing**; the original contact footprints and board position remain fixed.

The new supported contacts add two front pads and one rear pad:

| Location | Contact footprint | Installed stock space |
|---|---:|---:|
| Front, (27, −40.2) mm | 3.2 × 4.0 mm | 0.2615 mm |
| Front, (25, −52.1) mm | 4.8 × 1.2 mm | 0.2615 mm |
| Rear, (25, −52.1) mm | 4.8 × 1.2 mm | 0.7085 mm |

This gives **11 PCB pad locations: eight retained and three added**. Installed thickness includes adhesive. Do not stack a new pad over a retained pad. The narrow lower-right contact must land on bare laminate, clear solder and components, and support the board without bowing it. The rear land has a nominal 0.3944 mm gap to the adjacent header model; measure the actual populated board. See the [PCB manifest](../Verification/pcb/FINAL_INTEGRATION_MANIFEST.json) and [PCB-01 through PCB-05](../Verification/pcb/risk_register_pcb.json).

The [tapered-root screen](../Verification/pcb/support_load_screen.json) checks both lateral bending directions under an assumed 5 N contact load. Its highest calculated stress is approximately 2.46 MPa and its highest deflection is 0.0473 mm using an assumed effective modulus of 1,000 MPa. These calculations omit print defects, anisotropy, root stress concentration and board flexibility. Support connector housings during mating; the supports do not justify pulling on wires.

### Original speaker-tab clash corrected

The original speaker model intersected the original P01 upper internal curve by **4.2339 mm³**. This was an existing assembly conflict, separate from the keeper changes. A rounded internal **12.6 × 1.9 mm** pocket with floor at **Z = −2.35 mm** gives 0.30 mm nominal tab clearance. The revised nominal overlap is zero. The analytical front-skin lower bound at this pocket is **1.425 mm**; the outer fillet stays fixed. See the [measured before/after result](../Verification/passive/speaker_tab_clearance.json) and [PA-21][risk-PA-21]. Verify the received speaker tab and gasket seat without keeper force.

### Exterior checks and their limits

The [exterior classification](../Verification/controls/EXTERIOR_CLASSIFICATION.md) distinguishes visible outer surfaces, openings and caps from permitted changes to hidden receivers and inner return faces. A broad 0.8 mm surface-band subtraction also includes internal stock, so it is not treated as proof that every surface in that band is unchanged. Numerical coincidence failures were investigated with exact surface parameters, mutual face differences and edge/interior samples; they were not accepted merely by increasing a tolerance.

The [protected-region checks](../Verification/controls/protected_regions.json) and [matching report](../Verification/controls/exterior_matching_detailed.json) cover visible controls and actuator interfaces. F01, F02, M04, L01 and L02 retain the original STEP content. The authoritative selected exterior evidence is the [final native exterior summary](../Verification/controls/exterior_native_final/SUMMARY.md), bound to the final assembly by the [native provenance bridge](../Verification/controls/exterior_native_final/FINAL_NATIVE_PROVENANCE_BRIDGE.json). Earlier combined boundary diagnostics are historical. The native export refines one original B-spline trim by at most 0.000976 mm within its original 0.001035 mm stored tolerance; underlying analytic surfaces and nominal dimensions remain fixed, while edge coordinates are not bit-identical. Printed fit still depends on process compensation and finishing to the unchanged nominal geometry.

## Controls, cradles and removable captures

| Part | Disposition and mechanical change | Evidence and physical gate |
|---|---|---|
| **P03 — Play button** | Revised. Capture bars increase to **29 × 3.2 × 1.8 mm**. Original visible cap and contact nub remain. Direct P01 floors take the excess-travel load at a nominal **0.50 mm** inward movement. | [CTRL_P03][risk-CTRL_P03]. Check the loose bar roots, cap-edge presses, side fit and return. The inherited 0.10 mm outward clearance is not additional switch travel. |
| **P04 — Play switch clamp** | Revised. **1.75 mm plate, 2.75 mm arms and Ø6.8 mm ear backing**. Original countersunk seats remain because pan heads interfere with the PCB. Two Ø2 mm terminal-access bores preserve the switch seat. | [CTRL_P04][risk-CTRL_P04]. Keep solder and insulation inside the permitted access region; inspect ring roots and ears after tightening. Retain the specified M2 × 8 countersunk screws. |
| **P05 — PTT carrier** | Revised. The long printed rods are removed. Broad **3.4 × 8.6 mm sliders**, capture heads, internal backing and a central shell-supported stop replace the fragile projecting features and long bending span. The visible carrier and original nub stay fixed. | [CTRL_P05][risk-CTRL_P05], [CTRL_PTT_CENTRE][risk-CTRL_PTT_CENTRE]. Check centre and end presses, guide alignment, bond-film thickness and release with the case tightened. |
| **P06 — Volume-up button** | Revised. The unchanged visible cap joins a **9.2 × 2.0 mm stem**, **11.2 mm wide capture flange** and **0.45 mm root blends**. It enters an open guide before K01 is fastened; no retention leg is flexed through a hole. | [CTRL_P06][risk-CTRL_P06]. Check loose-part handling, upper/lower edge presses, guide fit and return. |
| **P07 — Volume-down button** | Revised. The same broad slider and flange architecture uses its own K02 keeper, avoiding a coupled volume mechanism. | [CTRL_P07][risk-CTRL_P07]. Confirm that pressing one button does not move or preload the other; preserve the routed J9 wire clearance. |
| **P08 — PTT switch cradle** | Revised. Roof thickness increases **1.0 → 1.6 mm**, with matching shell relief. The selected switch seat and terminals remain fixed. | [CTRL_P08][risk-CTRL_P08]. Install without snapping the roof over the switch. Measure pad compression and switch release. |
| **P09 — Volume-up switch cradle** | Revised. The same 1.6 mm roof treatment retains the original switch and terminal datums. | [CTRL_P09][risk-CTRL_P09]. Check actual switch-body fit and terminal insulation beside the battery and its keeper. |
| **P10 — Volume-down switch cradle** | Revised. The same supported roof and non-flexing installation sequence. | [CTRL_P10][risk-CTRL_P10]. Check the actual switch, lower wire approach and free return after closure. |
| **P17 — Lower PTT capture** | Replaced. A removable keeper captures the broad slider. A **1.5 mm roof**, **2 mm recessed ear floors** and two pan-head screws provide supported retention and a defined stop. | [CTRL_P17][risk-CTRL_P17]. Seat against rigid structure without pinching the slider. Match its stop to P18 and the P01 central stop. |
| **P18 — Upper PTT capture** | Replaced. Matching supported keeper removes the original long-rod interface and flex-to-install catch. | [CTRL_P18][risk-CTRL_P18]. Verify alignment with P17, battery clearance and full end-press return. |
| **K01 — Added volume-up capture** | Added. A removable **2.0 mm roof**, supported stop wall, broad cap-face stop lands and hard screw seats retain P06. The P02 floor is nominally 1.7 mm. | [CTRL_K01][risk-CTRL_K01]. Coupon-check the running fit; tightening must not close the moving channel. |
| **K02 — Added volume-down capture** | Added. Independent matching guide, stop and fastening for P07. | [CTRL_K02][risk-CTRL_K02]. Verify running fit and adjacent J9 wiring; the wire must stay in its retained route during operation. Release the documented common-link dressing and junction loop before screw service, then restore the final route. |

The [control build and assembly notes](../Verification/controls/CONTROLS.md) define dimensions, assembly order and coupon use. The [combined core checks](../Verification/controls/COMBINED_CONTROL_CHECKS.md) cover the default moving parts against 28 printed parts and 32 hardware groups: 28 press positions and 24 owning-shell insertion positions clear. These are rigid CAD samples, not a physical edge-press or fatigue test. Final wiring and stock require their separate integrated clearance results.

The final early bend of J9 pin 4 leaves **0.4456 mm** between its nominal Ø1.05 mm wire and the unmodified K02 keeper. Its Ø1.65 mm clearance sweep, which includes 0.30 mm radial allowance, also clears. No keeper notch is required, so the roof, stop and screw-seat stock remain intact. See the [source-hashed local check](../Verification/controls/final_j9_keeper_check.json).

### Stop selection and force path

The default side-control limit is **0.45 mm**. The play limit is **0.50 mm**. These are distances from the modeled reference position to printed mechanical stops, not validated safe travel for an unidentified switch variant.

Volume keeper options of **0.30, 0.40, 0.50 and 0.60 mm** change broad stop geometry. Select only after measuring the installed switch, pad stack and required travel. PTT alternatives require a **matched P01 central-stop version as well as both PTT keepers**; changing only P17/P18 does not make a complete alternative.

Before stop contact, a cap-edge press loads the slider and guide through a moment. After contact, the volume cap-face lands and PTT central bridge redirect the load into supported stationary structure. The play floors bypass the clamp as the primary excess-travel stop. These details address rocking and hard presses, not only axial translation. See [load paths and limits](../Verification/controls/STRENGTH_AND_TRAVEL.md).

The calculations use **5 N before stop contact and 10 N after contact** as screening cases, with hypothetical effective modulus **1,000 MPa** and stress screen **8 MPa**. For example, the volume roof screen reaches about **7.49 MPa / 0.087 mm** under the 5 N edge case; the PTT central bridge shortens the load path that otherwise left a large end-to-end deflection. These are not material allowables or user force ratings. Actual elastic motion after stop contact must fit within the verified switch overtravel margin.

## Speaker, microphone, lamp, antenna and battery retainers

| Part | Disposition and reason | Evidence and physical gate |
|---|---|---|
| **P11 — Lower speaker keeper** | Revised from a 4.4 × 1.4 mm beam to a **7.2 × 2.2 mm section**. Ø7.2 mm ears and Ø4.2 mm countersink mouths leave **1.5 mm side ligaments**. | [PA-05][risk-PA-05], [PA-06][risk-PA-06]. Load the speaker frame, not its diaphragm; qualify the actual keeper and gentle screw seating. |
| **P12 — Upper speaker keeper** | Revised with the same wider beam and supported countersinks. The separate P01 upper-tab pocket removes the original speaker collision. | [PA-05][risk-PA-05], [PA-21][risk-PA-21]. Check upper-tab and gasket seating before fastening. |
| **P13 — Microphone keeper** | Revised. Long frame rails deepen to **2.65 mm**; broad **1.85 mm pan-head seats** carry two M2 × 5 screws. The central opening and acoustic datum remain. | [PA-07][risk-PA-07], [PA-08][risk-PA-08], [PA-20][risk-PA-20]. Check both rail handling and board support, seal alignment, solder clearance and PTT return. |
| **P14 — LED keeper** | Revised. **Ø6 mm flat pan-head bearing stock** replaces splitting-prone countersink loading while preserving the optical saddle. Blind-hole depth is controlled. | [PA-09][risk-PA-09], [PA-10][risk-PA-10]. Keep tightening loads off the LED body and leads; test the insulated lead bundle and light output. |
| **P15 — Lower antenna retainer** | Replaced with a broad removable end clamp. An insulated carrier and controlled pads support the antenna; screw load does not pass through the antenna itself. | [FX-P15][risk-FX-P15]. Retain the specified nylon hardware, dielectric and routed coax. Qualify RF performance in the closed device. |
| **P16 — Upper antenna retainer** | Replaced with a matching end clamp. The fragile enclosing cable bridge is removed; cable restraint is handled separately. | [FX-P16][risk-FX-P16]. Check cable bend, service slack, insulation and clamp seating without antenna damage. |
| **P19 — Left battery keeper** | Revised. **3 mm plate**, supported **2.6 mm ear necks**, rounded roots, broad contacts and removable fastening replace concentrated pouch-retention loads. | [BAT19][risk-BAT19]. Use the inert maximum-size gauge first. The keeper must seat on its posts without compressing the pouch. |
| **P20 — Right battery keeper** | Revised with the same bridge architecture and bounded wire/terminal reliefs. The factory lead and protected battery tab retain a service route. | [BAT20][risk-BAT20]. Check the actual dressed pack, tab, cable, lower toe and PCB edge together. Do not substitute thicker pads indiscriminately. |
| **K03 — Added adapter cover** | Added. A hard-seated cover captures a passive FR4 adapter carrier and split silicone strain grommet. Two M2 × 6 pan screws now enter from the open rear through 2 mm ears, avoiding head clashes in the cable-support webs. Its 6 mm-deep crossbar has minimum 2.025 / 2.14 mm lower/upper rails; the rounded passage clears corrected insulation by 0.36 mm. The factory battery plug and leads stay intact. | [CTRL_K03_REAR_ACCESS][risk-CTRL_K03_REAR_ACCESS], [final cover evidence](../Verification/controls/K03_REAR_ACCESS_REVIEW.md) and [cover manifest](../Verification/controls/K03_TERMINATION_CLEARANCE_FINAL_MANIFEST.json). Preassemble and insert the soldered adapter/cover module from the open rear, then fasten it before the PCB; use the final matched base, cover and hardware. Verify polarity, connector keying, insulation and mechanical cable retention; soldered pins are not structural ties. |

The [passive-part screens](../Verification/passive/structural_screen.json) compare original and revised speaker/microphone sections under the same assumptions. The speaker beam estimate changes from **15.83 to 3.92 MPa** at 5 N; the two microphone rails change from **12.37 to 6.03 MPa** when sharing 5 N. The [battery keeper screen](../Verification/battery/keeper_load_screen.json) separately checks the ear neck, transition and main plate. All require coupons made with the intended material, orientation and postprocessing. None establishes drop or fatigue performance.

The [battery manifest](../Verification/battery/FINAL_INTEGRATION_MANIFEST.json) distinguishes a nominal 60 × 36 × 7 mm body from the supplier maximum **62 × 38.5 × 8.5 mm** envelope. The bare XY cavity is **62.6 × 39.1 mm**. These values are not an allowance for a swollen pack. Default contact films and optional nominal-only pads are different configurations: **replace, never stack**. Measure the received protected pack and the complete installed stock thickness.

## Final cable retention and shared clearances

The [fixture build notes](Fixture_Build_Notes.md), [final correction notes](Fixture_Final_Corrections.md) and [J9 harness instructions](J9_Harness_and_Stock.md) describe the selected cable assemblies and service sequence. Use their final integrated references; older route or restraint candidates are excluded.

| Feature | Final treatment | Evidence and remaining physical test |
|---|---|---|
| **J8 saddle beside J9 play wire** | Open the crossing to the rear so it leaves no 0.65 mm lip. The formed strap wraps onto the new vertical end face. | 26.3175 mm² nominal strap contact; 0.5081 mm saddle-to-wire and 0.3711 mm strap-to-wire clearance. **QF04B replaces QF04**. Qualify printed roots, adhesive peel, grip and service dressing. |
| **Antenna coax retention** | Two 4 mm-wide straps follow the existing curved shell lands and grip the cable against unbonded silicone half-saddles. | The manufacturer identifies an FEP jacket; **no chemical adhesion to it is credited**. The old RTV tacks and flat tape contours are withdrawn. **QF05** tests print-land adhesion and mechanical grip without coax damage. R5 remains a supplied-cable verification requirement. |
| **Speaker wiring beside PTT** | The shortened speaker lead 2 uses the rearward local bypass; splice 1 shifts 0.30 mm forward with its full Ø3.2 × 8 mm insulation reserve. | Lead 2 centerline is 45.716 mm with R3 bends. Factory start is still an inspection assumption. Verify actual exit, finished joints, retention and service slack; no battery factory wire is altered. |
| **Battery keeper wire ports** | Keep the full inboard spines and limit relief to the free port edge and a small upper-neck edge trim. | P19 spine remains 4.0 × 2.3 × 3.0 mm; P20 remains 2.5 × 7.0 × 3.0 mm after the final inward-riser relief; that relief removes 2.11862 mm³ from the free port corner and none from the anchor necks. The earlier CK neck screen remains approximately 6.98 MPa under the same hypothetical material assumptions. Inspect the local 1.336 mm rear shelf separately during handling tests. |

The antenna-to-maximum-battery planar gap is **5.15 mm**, and the PCB rear-plane gap is **7.4485 mm**; components can be closer. These are below Taoglas's 10 mm metal-spacing recommendation. Mechanical fit does not prove RF performance. No pull, adhesive, cable-fatigue, electrical or RF physical test has been reported as passed.

The final inward battery-lead channels leave local source-shell wall minima of **1.74808 mm and 0.999932 mm** to the original curved exterior. Both intact factory routes remain 100 mm in CAD with 0.20 mm nominal pair separation. Final exterior proof, actual cable length/dressing and local skin handling remain separate checks. See [the final fixture corrections](Fixture_Final_Corrections.md#inward-battery-lead-risers-and-preserved-exterior).

## Retained parts: why retention is deliberate

| Part | Why original geometry remains appropriate to retain | Required support and qualification |
|---|---|---|
| **F01 — Flexible rim / bumper** | Its exact contour and openings are part of the fixed exterior. The thin bridges are intended to work as flexible features; replacing them with a rigid print would change their behavior. | [PA-15][risk-PA-15]. Select and test a flexible material. Seat progressively around a closed shell; complete ten installation/removal cycles and inspect corners and opening bridges for tears. |
| **F02 — Flexible PTT grip** | The original 1.30 mm grip contour remains on the now better-supported PTT carrier. It does not need to become a rigid structural beam. | [PA-16][risk-PA-16]. Use one controlled 0.10 mm nominal bond stack, keep adhesive out of the guide, and test peel, shear and return through 1,000 centre/end actuations. |
| **M04 — Grille bezel** | The original 1.2 mm locating lip has broad perimeter support when assembled. Its vulnerable case is loose handling or force fitting, so the handling tray and supported installation address that case without changing the grille. | [PA-14][risk-PA-14]. Remove supports and trim mesh while supported; qualify the bond and scrim stack. Do not lever against the lip during removal. |
| **L01 — Lens fit proxy** | The original visible lens and continuous supported flange remain. The hidden shell flange pocket enlarges to Ø6.0 mm; retention should come from supported capture rather than an interference fit. | [PA-11][risk-PA-11], [PA-12][risk-PA-12]. The fixed Ø4.8 mm throat against a Ø4.7 mm neck leaves only **0.05 mm nominal radial clearance**. Measure the actual optic and coupon; restore the intended nominal fit through process control, never force the lens. |
| **L02 — Light-guide fit proxy** | The compact optical form is supported by its saddle. Geometry changes would affect optical alignment; controlling the contact stack is the appropriate treatment. | [PA-13][risk-PA-13]. Qualify clear optical material, the single 0.05 mm installed coupling layer, alignment and removal without straining the optic. An opaque proxy verifies fit only. |

## Screws: engagement, bottoming and seating

The [hardware schedule](Hardware_Schedule.md) specifies **32 screws** and distinguishes countersunk length, which includes the head, from pan-head length, which is measured under the head. Head diameter and height must fit the actual recess; an M2 or M2.5 label alone is insufficient.

| Joint | Potential engagement | Nominal tip margin | Key assembly point |
|---|---:|---:|---|
| Case closure | 5.35 mm | 0.65 mm | Original outside countersinks stay fixed. Measure the purchased head and verify flush seating. |
| P04 play clamp | 6.61 mm | 1.64 mm | Retain M2 × 8 countersunk hardware and the original seat; pan heads are excluded by PCB clearance. |
| Speaker keepers | 2.80 mm | 0.65 mm | Use M2 × 5 countersunk screws in the wider seats. |
| Microphone keeper | 3.15 mm | 0.65 mm | Use M2 × 5 pan screws; frame and screw-seat thickness differ. |
| LED keeper | 2.40 mm | 0.70 mm | Use M2 × 5 pan screws; inspect leads below the head region. |
| Antenna clamps | 1.80 mm | 0.62 mm | Retain the specified M2 × 3 nylon hardware and head pose. |
| Volume captures | 4.00 mm | 0.40 mm | Head seat Z = −12.7 mm; keeper-to-shell seat Z = −14.7 mm. Do not confuse the two planes. |
| PTT captures | 4.00 mm | 0.50 mm | Head seat Z = −15.5 mm; keeper-to-shell seat Z = −13.5 mm. Tightening must leave the slider free. |
| Battery keepers | 3.40 mm | 1.20 mm | The hard posts take screw load; the pouch does not. |
| Adapter cover | 4.00 mm | 0.60 mm | Rear-access pan-head seat Z = −8.5 mm; cover-to-post hard seat Z = −6.5 mm. The PCB must be removed for direct screwdriver access. |

These are nominal geometric margins, not verified thread strengths. See the [hardware evidence ledger](../Verification/hardware_schedule.json), [original hardware sections](../Verification/original_hardware_sections.json), [passive fastener checks](../Verification/passive/fasteners.json) and subsystem manifests. Printed blind-hole depth, screw-length tolerance, head seating and thread formation all consume margin. Qualify the pilot and thread method on coupons, use controlled hand seating, and reject splitting, stripping or bottoming. No universal tightening torque is specified.

## Physical gates that remain open

1. **Manufacturing and handling:** print the applicable fit, pilot, keeper and beam coupons in the same orientation, material and postprocessing as the intended parts. Measure the coupons before judging fit. Inspect loose roots, lips, guide roofs and screw ears after support removal.
2. **Battery and board:** use the measured inert maximum gauge before the real pack. Check the dressed battery, intact factory lead, PCB edge, all 11 PCB pad locations and installed adhesive thickness. Reject forced fit, pouch rubbing or preload, board bow and an assembly that requires screw draw-down.
3. **Actual switches:** establish contact-pair continuity and obtain the exact switch travel/overtravel limits. With a force gauge, aligned indicator and continuity tester, measure click and release in approximately 0.02 mm steps over at least three cycles. Do not discover an unknown switch's internal stop by forcing it.
4. **Installed controls:** choose the shortest reliable qualified stop configuration. Check zero unintended preload, centre and edge presses, independent volume buttons and return with the case tightened. Compare measured elastic motion after stop contact with the verified switch overtravel margin. A nominal 0.45 mm stop alone does not prove protection.
5. **Wiring, optics and acoustics:** inspect actual connector keying, joint insulation, bend paths, retention and service slack. Verify polarity before power. Test microphone, speaker and light output after closure, and RF performance with the retained antenna in the revised internal assembly.
6. **Repeated assembly and use:** complete ten service cycles and 1,000 actuations per control, recording force, release, wear, cracks and residual set. Progress to the documented 5 N service and brief 10 N stopped-load checks only after basic fit and return pass. These tests have not been performed by the CAD audit.

Any failed gate calls for a specific corrected process, stock choice or paired internal revision followed by the relevant recheck. The fixed exterior remains a design constraint throughout qualification.

[risk-BAT01]: Feature_Risk_Register.md#risk-BAT01
[risk-BAT19]: Feature_Risk_Register.md#risk-BAT19
[risk-BAT20]: Feature_Risk_Register.md#risk-BAT20
[risk-CTRL_K01]: Feature_Risk_Register.md#risk-CTRL_K01
[risk-CTRL_K02]: Feature_Risk_Register.md#risk-CTRL_K02
[risk-CTRL_P03]: Feature_Risk_Register.md#risk-CTRL_P03
[risk-CTRL_P04]: Feature_Risk_Register.md#risk-CTRL_P04
[risk-CTRL_P05]: Feature_Risk_Register.md#risk-CTRL_P05
[risk-CTRL_P06]: Feature_Risk_Register.md#risk-CTRL_P06
[risk-CTRL_P07]: Feature_Risk_Register.md#risk-CTRL_P07
[risk-CTRL_P08]: Feature_Risk_Register.md#risk-CTRL_P08
[risk-CTRL_P09]: Feature_Risk_Register.md#risk-CTRL_P09
[risk-CTRL_P10]: Feature_Risk_Register.md#risk-CTRL_P10
[risk-CTRL_P17]: Feature_Risk_Register.md#risk-CTRL_P17
[risk-CTRL_P18]: Feature_Risk_Register.md#risk-CTRL_P18
[risk-CTRL_PTT_CENTRE]: Feature_Risk_Register.md#risk-CTRL_PTT_CENTRE
[risk-CTRL_RECEIVERS]: Feature_Risk_Register.md#risk-CTRL_RECEIVERS
[risk-FX-K03]: Feature_Risk_Register.md#risk-FX-K03
[risk-FX-P15]: Feature_Risk_Register.md#risk-FX-P15
[risk-FX-P16]: Feature_Risk_Register.md#risk-FX-P16
[risk-PA-01]: Feature_Risk_Register.md#risk-PA-01
[risk-PA-03]: Feature_Risk_Register.md#risk-PA-03
[risk-PA-04]: Feature_Risk_Register.md#risk-PA-04
[risk-PA-05]: Feature_Risk_Register.md#risk-PA-05
[risk-PA-06]: Feature_Risk_Register.md#risk-PA-06
[risk-PA-07]: Feature_Risk_Register.md#risk-PA-07
[risk-PA-08]: Feature_Risk_Register.md#risk-PA-08
[risk-PA-09]: Feature_Risk_Register.md#risk-PA-09
[risk-PA-10]: Feature_Risk_Register.md#risk-PA-10
[risk-PA-11]: Feature_Risk_Register.md#risk-PA-11
[risk-PA-12]: Feature_Risk_Register.md#risk-PA-12
[risk-PA-13]: Feature_Risk_Register.md#risk-PA-13
[risk-PA-14]: Feature_Risk_Register.md#risk-PA-14
[risk-PA-15]: Feature_Risk_Register.md#risk-PA-15
[risk-PA-16]: Feature_Risk_Register.md#risk-PA-16
[risk-PA-20]: Feature_Risk_Register.md#risk-PA-20
[risk-PA-21]: Feature_Risk_Register.md#risk-PA-21
[risk-PCB-01]: Feature_Risk_Register.md#risk-PCB-01
[risk-PCB-04]: Feature_Risk_Register.md#risk-PCB-04

## Final adapter correction after the full assembly audit

The old adapter roots interfered with the carrier and all four edge pads. The final P01 seat clears them and backs the front pads with 2.8 ×3.0 mm stock. K03 now uses rear-access screw ears and full head support; it has zero nominal overlap with the complete P01. Its rear-access insertion and driver paths were checked with the main PCB/module removed.

The right pilot has 0.95 mm to the carrier cavity and 0.96161 mm to the J9 channel; the left CK2 channel was moved 1 mm inboard to leave 1.20548 mm. Both pilot floors leave 1.8999 mm to the original exterior. These specific supported patches require controlled tapping and the exact QF01B coupon; they are not universal printable-wall limits. [Final adapter seat and fasteners](Adapter_Final_Seat_and_Fasteners.md) gives the installation and qualification sequence. The original QF01 coupon and Y-axis screw poses are superseded.

## Final microphone soft-facing correction

The former facing edge crossed the formed strap ramp by 0.147692 mm³. The final 6 × 10.5 × 0.25 mm facing removes 0.50 mm from that free edge, giving 0.121268 mm clearance while retaining all five wire contact rows and 95.45% of its area. The strap, both printed bond lands and QF03 geometry are unchanged. Qualify the installed edge and pull restraint; no compression allowance is used to excuse the former overlap.

## Final independent check of K03 slot rails

K03 uses a 6 mm-deep crossbar, with the grommet-slot rails checked separately: lower minimum 2.025 mm and upper minimum 2.14 mm. The final rounded front opening leaves 0.36 mm around the corrected insulation so solder joints do not become the cable clamp. Final rail/web screens peak at 7.28 MPa using explicitly hypothetical properties; the earlier 6.94 MPa web-only result is superseded.

Assemble the carrier, header, insulation, pads, grommet and cover together outside the shell, then insert the module from the open rear before the PCB. Nine sampled rear positions pass; separate cover-only insertion past fixed solder joints is unsuitable. Use the actual final cover `580eec6470b4…` with QF01B and complete the physical qualification.

## Fixed PTT rear-pad overhang

The original pad entered the moving carrier after approximately 0.25 mm travel. Trimming only its 0.50 mm outboard overhang gives a 5.2 × 9 × 0.50 mm installed pad, preserving all measured bearing areas. Seven local translation positions through the default 0…0.45 mm stroke retain at least 0.30 mm sampled clearance; limited midstroke rocking also clears. The final full-reference PTT rerun also passes, with a 0.26250 mm conservative continuous clearance bound and eight clear midstroke rocking probes. All six pairs of simultaneously pressed control groups clear. Play and both volume controls retain their passing checks through exact unchanged-input and removal-only proofs. See the [final control integration review](../Verification/controls/FINAL_CONTROL_INTEGRATION_REVIEW.md). Confirm cut-edge placement, no adhesive overhang and reliable release through the physical service/actuation tests.

[risk-CTRL_K03_REAR_ACCESS]: Feature_Risk_Register.md#risk-CTRL_K03_REAR_ACCESS