# Feature risk register

133 feature entries cover all 25 original printed parts and all 3 added printed retainers. The source register linked in each entry contains the detailed subsystem evidence. Physical qualification remains open.

<a id="risk-PA-01"></a>

## PA-01 — Four closure joints at X +/-33.4, Y +/-56

**Components:** P01, P02

**Concern:** Short receiving threads strip or pull out; a long screw can still engage only a short thin receiver.

**Loading:** Initial thread formation, tightening, ten service cycles and case pull-apart load.

**Evidence:** Original axis sections show only 2.00 mm pilot-surrounding stock; M2.5 x14 reference extends into open cavity.

**Treatment:** Extend receivers to Z -6.0, retaining D2.1 pilots and original axes/head seats; add supported outboard ribs. Potential threaded material increases to 5.35 mm.

**Verification:** Valid one-solid passive shell and recorded before/after sections; final exterior/assembly checks; QP01 replicated joint coupons.

**Remaining test:** Qualify tap/thread-forming method and low seating torque on coupons. Run ten complete service cycles; reject any split, stripped thread or loose closure.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-02"></a>

## PA-02 — Upper receiver inboard faces beside maximum battery

**Components:** P01

**Concern:** Enlarged bosses can consume pouch clearance; aggressive relief can leave a fragile unsupported wall.

**Loading:** Battery installation, closed-case shock and tightening.

**Evidence:** Original D4.6 receiver reaches X31.1 while maximum battery reaches X31.0.

**Treatment:** Relieve inboard stock to X +/-31.4 below Z -7.75; preserve outboard support continuously. Local pilot-side wall is 0.95 mm, not a free snap arm.

**Verification:** Explicitly record 0.40 mm centred body gap and 0.10 mm beyond the 0.30 mm lateral clearance envelope; final battery insertion sweep and QP01 test.

**Remaining test:** Confirm residual printed wall is sound, receiver thread survives qualification and pack does not contact hardware at lateral travel limits.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-03"></a>

## PA-03 — Rear closure countersinks and surrounding shell

**Components:** P02

**Concern:** Countersink wedge loads split the seat or dish the rear skin.

**Loading:** Tightening and case closure.

**Evidence:** Original head recesses sit in curved corners; external head seats are fixed by the user constraint.

**Treatment:** Add four inboard-biased internal head bolsters ending at Z -17.2; retain original countersink and D2.9 shaft clearance.

**Verification:** Original boundary face comparison and maximum battery clearance; geometry check must include actual screws.

**Remaining test:** Use measured compatible 90-degree heads, establish seating torque on coupons, and confirm closure without screws pulling parts together.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-04"></a>

## PA-04 — Exterior and mating seam

**Components:** P01, P02, F01

**Concern:** A local reinforcement changes outside shape, creates an interference, or causes closure distortion.

**Loading:** Printing, fitting bumper and final closure.

**Evidence:** Exterior frozen to original R3.4 including 78 x150 x24 mm bare case, all openings, buttons, grille and seam.

**Treatment:** Construct only local internal masks from the original; retain F01 exactly. Review each changed interface with both shells present.

**Verification:** Source hashes, boundary-face retention, dimensions, seam/opening comparison, complete assembly and removal-path checks.

**Remaining test:** Printed halves must seat by hand before any screw is tightened; verify seam and bumper fit after ten openings.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-05"></a>

## PA-05 — Speaker screw ears and transverse beams

**Components:** P11, P12

**Concern:** Narrow countersink ligaments split; thin beam bends into the speaker or loses retention.

**Loading:** Loose handling, screw seating, vibration and servicing.

**Evidence:** Original keeper 1.4 mm thick x4.4 mm wide, approximately 0.24 mm side ligament at countersink mouth.

**Treatment:** Replace with 2.2 mm thick x7.2 mm wide capsule beams and D7.2 ears; D4.2 countersink mouth leaves 1.5 mm side ligament. Original contact plane Z -4.95 retained.

**Verification:** Interference checks, elementary beam screen, QP03 support jig and actual keeper strength coupon. Upper rear face Z -7.15 clears provisional maximum battery.

**Remaining test:** Establish gentle screw seating; test keeper with 5 N central padded load outside device; inspect ears after ten installations. Load speaker frame only.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-06"></a>

## PA-06 — Speaker blind screw pilots

**Components:** P01, P11, P12

**Concern:** Screw bottoms before clamp seats or breaks the front skin.

**Loading:** Assembly tightening.

**Evidence:** Original upper screw reference has approximately 0.09 mm floor margin.

**Treatment:** Use matched M2 x5 countersunk length at Z -7.15; pilot floor Z -1.5 gives 0.65 mm nominal tip clearance and 2.80 mm potential engagement.

**Verification:** Axis section and hardware envelope checks, including head diameter and angle.

**Remaining test:** Measure actual screw length and print hole depth; verify sample seating without bottoming. Do not substitute longer screws.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-07"></a>

## PA-07 — Microphone keeper screw seats

**Components:** P13, P01

**Concern:** Countersink wedging or blind-hole bottoming; reinforcement may collide with PTT.

**Loading:** Screw tightening, control movement and servicing.

**Evidence:** Original reinforced keeper 1.85 mm thick; original screw floor margin approximately 0.29 mm. Prior pan-head attempt collided with the old long PTT rod.

**Treatment:** Thicken the relieved ring rearward to 2.65 mm while preserving the optical/acoustic board datum; fill countersinks to broad D5.8 flat ears with 1.85 mm seating thickness, D2.3 clearance holes, M2 x5 pan heads and D4.4 rear head relief. Deepen pilots to -1.3 for 0.65 mm tip margin.

**Verification:** No passive-part clash against original non-control hardware; new PTT mechanism must clear pan heads through all travel and insertion positions. QP02 pilot coupons.

**Remaining test:** Verify board support, screw seating and full PTT edge presses with case tightened; measure real screw dimensions.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-08"></a>

## PA-08 — Mic board, bottom acoustic port and offset seal

**Components:** P13, MIC, MIC_SEAL

**Concern:** Fastening bends board, crushes components or blocks acoustic path.

**Loading:** Seating, pad compression and acoustic operation.

**Evidence:** Original microphone port is offset and seal reserves about 1.8 mm installed space; rear reliefs avoid components.

**Treatment:** Preserve board lands, port alignment and component reliefs. Keep screw clamp load on hard keeper/boss seats, use only the measured installed compliant stack.

**Verification:** Review support/contact faces, seal opening and component clearances in full assembly.

**Remaining test:** Check actual populated breakout and seal grade/thickness; acoustic test after closure; reject board bow or pad-induced component loading.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-09"></a>

## PA-09 — LED keeper screw ears and blind pilots

**Components:** P14, P01

**Concern:** Countersink splitting, keeper bending or screw bottoming.

**Loading:** Insertion, tightening and removal.

**Evidence:** Original small saddle, countersinks and approximately 0.29 mm tip floor margin.

**Treatment:** Broaden flat bearing stock to D6.0 around two M2 x5 pan-head joints; D2.3 holes, seat -10.9, head rear -12.5; retain optical saddle/lead relief.

**Verification:** Geometry/hardware checks; nominal 2.4 mm engagement and 0.7 mm tip margin; QP02 screw-method trial.

**Remaining test:** Confirm no torque transferred into lamp package or leads, no saddle crack, and repeat ten service cycles.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-10"></a>

## PA-10 — LED package, coupler and four lead exits

**Components:** P14, LED, L02

**Concern:** Keeper preload chips optics or cracks lamp; wire pull bends soldered leads.

**Loading:** Lamp installation, cable connection and servicing.

**Evidence:** Four insulated leads share limited rear space with the keeper and light coupler.

**Treatment:** Retain supported saddle and original optical datum; seat keeper on hard stops and preserve insulated lead exit/strain-relief path.

**Verification:** Full hardware/harness collision review plus nominal optical-contact review.

**Remaining test:** Measure actual lamp, lead bends, insulation and coupling film; electrical/optical test in tightened case.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-11"></a>

## PA-11 — Lens rear flange pocket and fixed visible throat

**Components:** P01, L01

**Concern:** A brittle interference fit chips lens or splits the seat.

**Loading:** Insertion/removal and an external finger press.

**Evidence:** Original D5.4 flange in D5.6 rear seat gives 0.10 mm radial nominal clearance; neck D4.7 in a fixed D4.8 throat is tighter.

**Treatment:** Enlarge only hidden rear flange pocket to D6.0; preserve shoulder Z -2.15 and all visible lens/aperture geometry. Use drop fit and rear capture, not press-fit retention.

**Verification:** L01 is retained byte-for-byte; internal mask and exterior boundary check; QP04 coupons cover flange seats and fixed throat.

**Remaining test:** Measure real clear polymer part and cleaned throat. If fixed throat fails coupon fit, adjust manufacturing compensation/finishing to nominal; do not force or enlarge nominal exterior.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-12"></a>

## PA-12 — Lens flange and visible cap

**Components:** L01

**Concern:** Thin radial shoulder chips during loose handling or overloading.

**Loading:** Handling before capture and pressing after assembly.

**Evidence:** Flange D5.4 x1.35 axial thickness; continuous annular shoulder rather than a cantilever arm.

**Treatment:** Retain geometry with continuous supported seating and rear retention; handle in a tray and fit only after the receiver is clean.

**Verification:** Recorded flange dimensions, contact support and fit coupon; unchanged geometry proof.

**Remaining test:** Inspect clear production material for chips; confirm captured lens resists a modest finger press without movement. Opaque printed proxy only checks fit.

**Status:** Retained geometry with documented supported use and fit qualification

<a id="risk-PA-13"></a>

## PA-13 — Right-angle coupler and thin coupling film

**Components:** L02, OPTICAL_FILM

**Concern:** Small optic chips under uneven compression; adhesive squeeze-out blocks light.

**Loading:** Assembly, keeper seating and thermal cycling.

**Evidence:** Original coupler is compact 4.2 x4.2 x5.55 mm; coupling film is 0.05 mm installed space.

**Treatment:** Retain optical geometry and supported saddle; use a single controlled thin coupling layer and remove compressive load from the fastener path.

**Verification:** Original geometry retained; full package/keeper review and light-path alignment checks.

**Remaining test:** Use clear optical polymer and a qualified coupling/bond process; inspect for squeeze-out and test light output.

**Status:** Retained geometry; functional clear optics require physical test

<a id="risk-PA-14"></a>

## PA-14 — Grille locating lip and mesh/scrim perimeter

**Components:** M04, GRILLE_MESH, SCRIM

**Concern:** 1.2 mm lip chips while loose; force fitting distorts grille; bond peels during removal.

**Loading:** Support removal, mesh installation, handling and servicing.

**Evidence:** Original M04 lip 1.2 mm and plate envelope 1.65 mm; installed perimeter is broadly supported by shell and adhesive.

**Treatment:** Retain exact exterior and grille geometry; use JP01 clearance handling tray for support and a non-interference locating fit. Finish mesh edges, use one controlled perimeter bond stack.

**Verification:** Unchanged STEP hash/geometry, locating/support section and actual fit review.

**Remaining test:** Trim burrs while supported; test bond with actual finish/stock, prevent scrim from obstructing seating, and avoid levering the lip during removal.

**Status:** Retained geometry with assembly support and bond qualification

<a id="risk-PA-15"></a>

## PA-15 — Flexible rim, corner turns and opening bridges

**Components:** F01

**Concern:** Tearing at thin bridges, excessive stretch or brittle rigid-material substitution.

**Loading:** Installation/removal and corner impact.

**Evidence:** Original sampled minimum about 1.187 mm; contour is frozen.

**Treatment:** Retain exact flexible contour; select a flexible process/material and qualify stretch/tear behavior. Seat gradually around the perimeter on a closed, unforced shell.

**Verification:** Exact geometry comparison, opening alignment and flex fit check.

**Remaining test:** Ten rim installation/removal cycles plus edge inspection in each proposed flexible material. A rigid proxy cannot establish durability.

**Status:** Retained contour; material/process must satisfy flex and tear tests

<a id="risk-PA-16"></a>

## PA-16 — Talk grip and its 0.10 mm bond stack

**Components:** F02, PTT_BOND

**Concern:** Edge peel, tearing or excess bond thickness blocks return.

**Loading:** Side presses, repeated control use and removal.

**Evidence:** Grip is 1.30 mm thick with 0.10 mm nominal bond; visible outline/protrusion are fixed.

**Treatment:** Retain exact grip and bond datum; use full supported bond area on the revised carrier with no adhesive entering guides/stops.

**Verification:** Control motion includes grip; original geometry retained.

**Remaining test:** Adhesive compatibility and 1,000 centre/end actuations with force/release check; inspect edge peel and grip shear.

**Status:** Retained exterior; bond and cyclic test required

<a id="risk-PA-17"></a>

## PA-17 — All pads, films, seals and component contact surfaces

**Components:** SOFT_STOCK, P01, P02

**Concern:** Doubled layers or free-stock thickness adds preload; foam creep unloads capture or bows electronics.

**Loading:** Initial assembly, closure, temperature exposure and servicing.

**Evidence:** Original reference uses installed-space proxies, not purchased free thickness or validated compression behavior.

**Treatment:** Replace superseded battery/antenna/control layers per new schedules; keep one ledger of installed thickness including adhesive. Hard-seated retainers define closure, not foam compression.

**Verification:** Every modeled soft-stock reference and stack appears in final schedule; closed-case interference and contact review.

**Remaining test:** Measure free and installed thickness/force of selected stock; verify no PCB bow, pouch pressure or unintended button activation; reject doubled legacy shims.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-18"></a>

## PA-18 — Support removal, loose handling, driver access and teardown

**Components:** ALL_PRINTED, ALL_HARDWARE

**Concern:** A sound assembled component breaks before installation or during removal.

**Loading:** Postprocessing and every service step.

**Evidence:** Failure photos and user reports show damage during assembly, so in-use strength alone is insufficient.

**Treatment:** Use broad removable parts, clearance insertion, a supported work surface and documented removal order. Include every added part/tool in manifest; avoid pushing tiny features to release supports.

**Verification:** Part-by-part handling instructions, insertion/removal checks and printed coupons.

**Remaining test:** Ten complete assembly/service cycles with magnified inspections, consistent tooling and recorded failures. No power driver until a qualified torque process exists.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-19"></a>

## PA-19 — Process qualification coupons and grille handling tray

**Components:** QP01, QP02, QP03, QP04, JP01

**Concern:** Coupon does not reproduce weak direction or support removal, producing a misleading pass.

**Loading:** Coupon printing, postprocessing and destructive tests.

**Evidence:** Geometry coupons reproduce pilot, bearing and support features; test bodies are not product parts.

**Treatment:** Print in the same material, orientation, cure/thermal treatment and machine profile as the actual feature. Label variants using the coupon map.

**Verification:** Valid one-solid STEP/STL and documented nominal dimensions.

**Remaining test:** Record actual dimensions, screw seating/strip behavior, beam load/deflection, lens fit and handling; a failed coupon blocks that process/profile.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-20"></a>

## PA-20 — Long microphone-frame rails and corner transitions

**Components:** P13

**Concern:** Thin ring bends or breaks before installation; unsupported point loading can damage a retained but unbroken part.

**Loading:** Loose-part handling, seating and pad reaction.

**Evidence:** Original long rails approximately1.55mm wide by1.85mm thick; a two-rail5N simplified screen exceeds the hypothetical8MPa allowable.

**Treatment:** Increase ring thickness rearward to2.65mm, preserving screw-seat plane and central component/wire opening. Retain original rounded corners; no forced flex during insertion.

**Verification:** QP05 jig supports the actual part at its23mm screw spacing. Each of two17.5mm-span rails screens at approximately6.03MPa under2.5N; model does not resolve ear/sideframe compliance. Full PTT/harness clearance check.

**Remaining test:** Test5N total over both rails and2.5N separately per rail; no crack or residual set. The part must be handled by broad ear/rail regions, not levered on a corner.

**Status:** CAD treatment prepared; physical qualification pending

<a id="risk-PA-21"></a>

## PA-21 — Speaker upper central tab, X +/-6, Y67.61..68.90

**Components:** P01, speaker, speaker gasket

**Concern:** Original rigid speaker tab intersects the inner curved case by4.234mm3, forcing assembly or lifting its seat.

**Loading:** Speaker insertion, keeper tightening and closure.

**Evidence:** Independent Common on original R3.4 and original speaker reproduces the same overlap.

**Treatment:** Rounded internal12.6x1.9mm relief, floorZ-2.35, nominal0.30mm tab clearance, unchanged external upper fillet.

**Verification:** Zero revised nominal tab overlap; analytical front-skin lower bound1.425mm; complete external/collision checks.

**Remaining test:** Measure actual speaker tab/gaskets and confirm seated acoustic component without keeper force. Inspect roof under assembly/handling.

**Status:** CAD revised; physical qualification pending

<a id="risk-PCB-01"></a>

## PCB-01 — Four original front/rear support pairs

**Components:** P01, P02, PCB, PCB_SUPPORT_STOCK

**Concern:** Small supports flex, split at roots or transmit concentrated pad load into board.

**Loading:** Loose handling, closure, connector insertion/pull and service.

**Evidence:** All eight original soft supports are2.5x4.5mm footprints at(-27,-33.7),(-27,10.2),(27,8),(27,17).

**Treatment:** Retain the four paired contact datums and stock envelopes; add tapered root backing to both shells. Left front upper root flares away from PTT terminals; left rear lower root fits between J10 andUSB.

**Verification:** All eight backing masks checked against original electronics and other printed parts; final all-new harness/control check required. Tapered-post load screen records both lateral directions.

**Remaining test:** Confirm each printed root is continuous/sound and inspect after ten service cycles. Measure pad compression rather than assuming free stock thickness.

**Status:** CAD treatment prepared; integrated and physical gates pending

<a id="risk-PCB-02"></a>

## PCB-02 — Lower-right PCB edge nearJ1

**Components:** P01, P02, PCB, PCB_SUPPORT_STOCK

**Concern:** Large unsupported board overhang permits board bending and connector stress.

**Loading:** Connector insertion, closure and service.

**Evidence:** Original has no lower-right support pair; actual laminate boundsY-53.04..26.96,Z-14.3015..-12.9715.

**Treatment:** Add matching front/rear4.8x1.2mm contact lands at(25,-52.1), with broad tapered roots. Rearroot flares toward lowerY so it clearsJ1 by0.3944mm.

**Verification:** Exact PCB face and header distance checked; frontland-to-oppositeshell gap0.4684mm. No collision in subsystem candidate.

**Remaining test:** Check actual boardedge/J1 solder and pad stack; narrow availablecontact must sit entirely on bare laminate. No preload-induced board bow.

**Status:** CAD treatment prepared; integrated and physical gates pending

<a id="risk-PCB-03"></a>

## PCB-03 — Mid-right front backing under side-header area

**Components:** P01, P02, PCB, PCB_SUPPORT_STOCK

**Concern:** PCB bends when a side connector is inserted or operated.

**Loading:** Mating and cable insertion.

**Evidence:** Selected sideheaders occupy rear board area; adding a rear block directly behind them would collide.

**Treatment:** Add3.2x4.0mm supportedfrontland at(27,-40.2). Preserve header poses; harness strain retention takes cable pull.

**Verification:** Nominal frontstock0.2615mm touches actual boardfront without overlap; all original components clear.

**Remaining test:** Support connector housings by hand during mating; verify actual boarddeflection and cable strain retention, not pad friction alone.

**Status:** CAD treatment prepared; integrated and physical gates pending

<a id="risk-PCB-04"></a>

## PCB-04 — Long surrounding board edge/location rails

**Components:** P01, P02, PCB, PCB_SUPPORT_STOCK

**Concern:** Thin edge rail or cut wire window cracks; lateral board movement loads fixedUSB/header interfaces.

**Loading:** PCB insertion/removal, wire routing and connector pull.

**Evidence:** Original sections atZ-12.7,-8,-15.02,-18 show continuous host-backed shell walls/rails and discrete support lands; antenna cablebridge is replaced separately.

**Treatment:** Retain host-backed locating walls; addrootbacking at load stations. Cablecutouts use single broad open windows with supported remaining walls instead of thin fins.

**Verification:** Dimensioned original section review plus final wire-window minimum sections and nominal edge fit; no claim that a visual minimum establishes strength.

**Remaining test:** PCB must drop into locators without forced flex; confirm USBalignment and lateral reaction under actual connector use and ten servicecycles.

**Status:** CAD treatment prepared; integrated and physical gates pending

<a id="risk-PCB-05"></a>

## PCB-05 — Eleven installed PCB pad locations after revision

**Components:** P01, P02, PCB, PCB_SUPPORT_STOCK

**Concern:** Doubled stock, adhesive thickness or excessive compression bows the board.

**Loading:** Case closure and thermal/service cycling.

**Evidence:** Originalfrontinstalled0.2615mm/rear0.7085mm; three added stockpieces use same matchingfaces.

**Treatment:** Keep one layer perlistedlocation including adhesive. Retain original8, add3; qualify selectedinsulating stock for actual compression.

**Verification:** Eleven-item finalstockledger and fullclosure check; no numerical materialcompressive property assumed.

**Remaining test:** Measure actual free/installed stack and record boardflatness. Case must close byhand without screwdrawdown, rocking or unintended actuation.

**Status:** CAD treatment prepared; integrated and physical gates pending

<a id="risk-BAT01"></a>

## BAT01 — Main bay and upper corners

**Components:** P02, battery

**Concern:** Zero-clearance forced insertion splits tall rails; oversize pouch clashes with originalcorner skin

**Loading:** Top insertion/removal and package dimensional variation

**Evidence:** Original bare60.52×36.52 with0.26liners reduced tonominal60×36, whilelinkedmaximum62×38.5×8.5

**Treatment:** Bare62.6×39.1 lowcradle, no defaultside liners, originalexterior retained; repositionmaxbody toY27.28…65.78/Z−16.6…−8.1

**Verification:** Valid1solid; sampled/inert insertion andservice-sweepchecks; exactsampledP02skinmin0.952935mm

**Remaining test:** Rootexactfullouterboundaryproof; actualprintfit; localthin curvedcorner handling/loadqualification

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT02"></a>

## BAT02 — Upper bay and four head pockets

**Components:** P01

**Concern:** Internalclearancecuts maythin rigid exterior skin

**Loading:** Handling/case closure/point impact

**Evidence:** New-headpocketmin1.098307mm afteranchorinboardmove; skin mapsinclude changedfaces and approximatearea/span

**Treatment:** Anchors|X|33.4; matched localhead/toe/plateclearance ratherthan broad exteriorchanges

**Verification:** Valid1solid and no unintendedstaticintersections; directional frontclearance0.25

**Remaining test:** Nativewatertight export and localprocessskinqualification; rootcompleteexteriorproof

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT19"></a>

## BAT19 — Plate, neck, ears, locating toe and outward-open wire port

**Components:** P19

**Concern:** Neck bending, hole-edge splitting, pouch pointload, or wire pinching

**Loading:** 5Nservice perkeeper; conservativeone-ear concentration included

**Evidence:** 3mmmainplate,2.6mmoutboardneck/seat,2mminboardtransition,OD4.8ear/D2.4hole; fullsingle-ear grosssectionstressmax7.42MPa againsthypothetical8MPa

**Treatment:** Wideplate androundedroots, supported deepoutboardneck, twoseparatedcontactfilms perkeeper, removablefastening onrigidstops; no pouchpreload

**Verification:** STEPvalid1solid andSTLwatertight; packet/service-sweep clear; keeper_load_screen.json

**Remaining test:** Printactualcouponand5Nscreen, screwfit, tenservicecycles andretention/rocking inspection; notch/screw/plate stressconcentrations notcertifiedbybeammodel

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT20"></a>

## BAT20 — Plate, neck, ears, locating toe and outward-open wire port

**Components:** P20

**Concern:** Neck bending, hole-edge splitting, pouch pointload, or wire pinching

**Loading:** 5Nservice perkeeper; conservativeone-ear concentration included

**Evidence:** 3mmmainplate,2.6mmoutboardneck/seat,2mminboardtransition,OD4.8ear/D2.4hole; fullsingle-ear grosssectionstressmax7.42MPa againsthypothetical8MPa

**Treatment:** Wideplate androundedroots, supported deepoutboardneck, twoseparatedcontactfilms perkeeper, removablefastening onrigidstops; no pouchpreload

**Verification:** STEPvalid1solid andSTLwatertight; packet/service-sweep clear; keeper_load_screen.json

**Remaining test:** Printactualcouponand5Nscreen, screwfit, tenservicecycles andretention/rocking inspection; notch/screw/plate stressconcentrations notcertifiedbybeammodel

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT03"></a>

## BAT03 — AnchorsX±33.4;leftY44.4/50.9,right37.5/50.9

**Components:** P02, 4newkeeperposts, 4M2×6screws

**Concern:** Pilot interference or excess tightening splits post; insufficient thread engagement strips receiver

**Loading:** Keeper installation/removal

**Evidence:** OD4.6 clippedatbayface31.3;D1.7pilot,minlocalpilotwall1.25;3.4threadengagement,1.2tipfloor;headmaxD4×1.6

**Treatment:** Broad lowroots mergeintooriginalsideskin; hardseat−8.4,panseat−5.8; screwforcebypasses pouch

**Verification:** Valid joined shell; contact/clearances and nominal thread overlap checked

**Remaining test:** ActualM2head dimensions, pilotcoupon1.6–1.9 processselection, tenassemblycycles; no unverifiedtightening torque prescribed

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT04"></a>

## BAT04 — Rear support, front keeper faces and lower toe faces

**Components:** 2rear support pads, 4defaultcontactfilms, 2toe liners

**Concern:** Over-thick stock preloads pouch; absentstock allows rattling/rubbing

**Loading:** Pack retention andservice travel

**Evidence:** Rear14.5×27.5×0.70;contacts7.5×3×0.10;toeliners8.7×0.20×2.2, allinstalledthicknessincladhesive

**Treatment:** Soft nonabrasive insulating purchasedstock; keepcontacts separate fromtabport; clear defaultmax pack .20front and .10lowerY

**Verification:** CAD stock poses plusbounded axis-alignedsweep; no bodypreloadmodelled

**Remaining test:** Measureinstalledstock andactualpouch; rejecthard/abrasiveprintsubstitutes, bubbling/stacking or compressednegativegap

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT05"></a>

## BAT05 — Samefourcontactlocations

**Components:** 4optional NOMINAL_ONLY frontpads

**Concern:** Usingthick nominalpackpads withmaximum pack squeezes pouch

**Loading:** Assembly variantselection

**Evidence:** Optional1.40installed replaces0.10films; maximum8.5packwouldinterfere, explicitlydisallowed

**Treatment:** Useonlywhere measuredlocalgap≥1.60; fourpads7.5×3; neverstackwithdefaultfilm

**Verification:** Nominal7mmpack leaves .40freefrontgap; CADvariantsseparated/hidden

**Remaining test:** Recordselectedstock;maxgaugeconfiguration mustdefaultto0.10films

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT06"></a>

## BAT06 — Lowerpouch edge atY27.18min versusPCBedgeY26.96

**Components:** battery, PCB, 2toe liners

**Concern:** Pouch abrasion onPCBedge due movement/tolerance/rocking

**Loading:** Removal,packtilt andretention

**Evidence:** Centredgap.32;bare−.30Ytravelwouldleave.02;0.20toe linerslimitnominalminimumto.22

**Treatment:** Broadfrontsidetoes abovePCBplussoftendliners; insert/removeinZ withfrontandkeepersremoved, keepclear ofPCBedge

**Verification:** Exacttranslation-sweep PCBdistance0.2199999mm, positive; nominalbody/tab rearinsertion clears

**Remaining test:** HOLD release ifactualboard/pouch/print/padstack orrockingloses apositive nonabrasivegap. Translationcheck isnotsoftpouch/tiltsimulation.

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT07"></a>

## BAT07 — Righttab after180°inplanerotation; risersY47.65

**Components:** factorybattery lead, factoryPHplug, protectedtab, keeperports

**Concern:** Wirepinch, damagedprotectedtab, insufficientleadlength orincorrectadapterpolarity

**Loading:** Caseclosure andservice

**Evidence:** Originalnominaltabpose retained/rotated; publishedrectangularmaxdoesnotverifyreceivedtabdress

**Treatment:** Preservefactorylead/plug/tape/protection; fixturesownscompactremovableadapter androutedconductors;bothkeeperportsopenoutward

**Verification:** Body/tabstraightinsertionchecked; exactfixturesintegrationseparate

**Remaining test:** Actual intactlead/connector/tabmeasurements, finalrouteclearance/strainrelief/polaritycheck; no cut/reterminateauthorization inferred

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT08"></a>

## BAT08 — Inertmaxgauge, XYfitcoupon androot/keepertestcoupons

**Components:** QB01, QB02, QB03variants, QB04

**Concern:** Uncalibrated print givesfalsefit; couponpassing mistakenforfullpartqualification

**Loading:** Shopcalibration andfirstarticle

**Evidence:** Rectangularmax62×38.5×8.5;barecoupon62.6×39.1;postpilot1.6/1.7/1.8/1.9;exactcroppedkeeper

**Treatment:** Measuregaugefirst; useintendedprocess/orientation/finish; selectpiloton coupon thenupdateapplicableCADexplicitly

**Verification:** ExportedvalidSTEP/STL; physicaltestsnotperformed

**Remaining test:** Couponandfullcase fit/load/servicechecks; neverforce liveLiPoforinspection

**Status:** CAD screened; physical qualification pending

<a id="risk-BAT_FINAL_CONTACT"></a>

## BAT_FINAL_CONTACT — P19 lower ear near(-33.4,44.4); P20 outboard lower locating toe

**Components:** P01, P19, P20, upper volume switch

**Concern:** Interference in final assembly transfers closure/retention force into a keeper or switch terminal.

**Loading:** Shell closure and battery service.

**Evidence:** Full integration found0.398281mm³ P19/P01 and0.210934mm³ P20/upper-volume terminal overlaps.

**Treatment:** Bounded P01 pocket preserves1.75mm pilot-side stock at adjacent P18 receiver and remains2.449mm from classified exterior. P20 toe notch removes1.561mm³ while retaining8.55mm full-height toe width,3.0mm lower and1.7mm upper local stock; liner and keeper anchors remain intact.

**Verification:** Valid one-solid P20 and corrected P01 trial; P19 intersection becomes zero. See final_neighbor_corrections.json.

**Remaining test:** Root exact all-component/native boundary checks; printed toe/ear and adjacent receiver handling qualification.

**Status:** CAD correction delivered for final native integration.

<a id="risk-CTRL_P03"></a>

## CTRL_P03 — Play cap, bar ends and root connections

**Components:** P03, P01

**Concern:** Cap flexure, broken capture bars or pocket binding

**Loading:** Loose handling, edge pressing, insertion and hard stop

**Evidence:** Original bars29x2.4x1.2mm; exterior cap fixed.

**Treatment:** Bars29x3.2x1.8mm; matched0.3mm side gaps; direct shell-backed bar stop floors at0.50mm.

**Verification:** Valid STEP;11 travel positions; positive P01 and P04 witnesses at0.51; actual section and local bar/floor screens.

**Remaining test:** Measure edge travel, printed fit and return;10 service and1000 actuation cycles. No endurance test performed.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P04"></a>

## CTRL_P04 — Clamp beam, raised ring, mounting ears and solder access

**Components:** P04, original P04 countersunk screws

**Concern:** Beam flexure, screw-seat splitting, terminal pinch

**Loading:** Switch load, tightening and service

**Evidence:** Original plate1.4; fixed PCB blocks pan-head conversion.

**Treatment:** Plate1.75, arms2.75, earsØ6.8. Original countersink datums retained. TwoØ2 terminal-access bores remove1.33424mm3 total; source switch seat unchanged.

**Verification:** One solid STEP; static/play motion pass; actual section screen includes ring/core; root full harness audit.

**Remaining test:** Actual switch seating, preload, torque-to-seat, PCB gap and terminal joints; use original M2x8CS screws.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P05"></a>

## CTRL_P05 — PTT skin, internal backing, slider roots and heads

**Components:** P05

**Concern:** Broken long rods/webs, skin bending and switch overtravel

**Loading:** Uncaptured handling, end/centre press and hard press

**Evidence:** OriginalØ2.4 long rods,1.2webs/skin and1.05heads. End-only stop model predicted0.47mm extra centre flex at10N.

**Treatment:** Rods eliminated;3.4x8.6 broad sliders and6x8.6x1.8heads. Added inset internal backing/lower spine. Direct central P01 bridge shortens hard-stop load path.

**Verification:** 35 side-motion samples plus centre-stop witnesses; section screens distinguish before/after stop; sampled rear insertion.

**Remaining test:** Physical off-axis fit, coupled guides and actual installed switch travel margin including elastic deflection.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P06"></a>

## CTRL_P06 — Original visible cap and new stem/flange roots

**Components:** P06

**Concern:** Root/head break, cap bending and slider rocking

**Loading:** Handling, edge press, outward pull and overtravel

**Evidence:** Reported broken volume legs; original1.2mm legs/1.05heads.

**Treatment:** 9.2x2.0 stem,R0.45 roots;11.2x2.0x2.6 flange; broad cap-face stop lands; full cap/nub preserved.

**Verification:** Zero protected-cap and contact-nub differences;35 travel positions each; full cap section screens and edge moment/couple calculation.

**Remaining test:** First-article edge travel and return; actual process/force,1000 actuations; simple beam models do not certify local point contact or fatigue.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P07"></a>

## CTRL_P07 — Original visible cap and new stem/flange roots

**Components:** P07

**Concern:** Root/head break, cap bending and slider rocking

**Loading:** Handling, edge press, outward pull and overtravel

**Evidence:** Reported broken volume legs; original1.2mm legs/1.05heads.

**Treatment:** 9.2x2.0 stem,R0.45 roots;11.2x2.0x2.6 flange; broad cap-face stop lands; full cap/nub preserved.

**Verification:** Zero protected-cap and contact-nub differences;35 travel positions each; full cap section screens and edge moment/couple calculation.

**Remaining test:** First-article edge travel and return; actual process/force,1000 actuations; simple beam models do not certify local point contact or fatigue.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P08"></a>

## CTRL_P08 — Cradle roof and side rails

**Components:** P08, P01

**Concern:** Roof/rail damage, switch mis-seat or terminal strain

**Loading:** Loose handling, assembly and switch force

**Evidence:** Original roof1.0mm; nominal NOT_OEM switch geometry.

**Treatment:** Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.

**Verification:** Valid one-solid STEP and static/reference checks;5N roof screen6.39MPa at hypothetical allow8.

**Remaining test:** Measure actual switch and solder joints; avoid loading terminals; retain cradles until closure.10N direct roof load is outside accepted service screen.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P09"></a>

## CTRL_P09 — Cradle roof and side rails

**Components:** P09, P01

**Concern:** Roof/rail damage, switch mis-seat or terminal strain

**Loading:** Loose handling, assembly and switch force

**Evidence:** Original roof1.0mm; nominal NOT_OEM switch geometry.

**Treatment:** Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.

**Verification:** Valid one-solid STEP and static/reference checks;5N roof screen6.39MPa at hypothetical allow8.

**Remaining test:** Measure actual switch and solder joints; avoid loading terminals; retain cradles until closure.10N direct roof load is outside accepted service screen.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P10"></a>

## CTRL_P10 — Cradle roof and side rails

**Components:** P10, P01

**Concern:** Roof/rail damage, switch mis-seat or terminal strain

**Loading:** Loose handling, assembly and switch force

**Evidence:** Original roof1.0mm; nominal NOT_OEM switch geometry.

**Treatment:** Roof1.6 toward front with paired P01 relief. Original seating and terminal geometry retained; face-down assembly without snap flex.

**Verification:** Valid one-solid STEP and static/reference checks;5N roof screen6.39MPa at hypothetical allow8.

**Remaining test:** Measure actual switch and solder joints; avoid loading terminals; retain cradles until closure.10N direct roof load is outside accepted service screen.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P17"></a>

## CTRL_P17 — PTT keeper roof, recessed ears and end stop

**Components:** P17, P01, P02

**Concern:** Guide break, pinching, coupled binding or ear splitting

**Loading:** Screw tightening, edge pressing, outward capture

**Evidence:** Original tube wall/ear1.2mm and0.1radial gap.

**Treatment:** Broad captured guides with1.5roof;2mm recessed ear floors; hard seats;0.3nominal guide gaps. Recessed M2x6 pan heads.

**Verification:** Static/35-motion checks; screw-head and battery/mic checks; all positive stop/capture witnesses.

**Remaining test:** Both keepers and P01 central stop must match stroke. Native combined audit plus measured guide return and service cycles.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_P18"></a>

## CTRL_P18 — PTT keeper roof, recessed ears and end stop

**Components:** P18, P01, P02

**Concern:** Guide break, pinching, coupled binding or ear splitting

**Loading:** Screw tightening, edge pressing, outward capture

**Evidence:** Original tube wall/ear1.2mm and0.1radial gap.

**Treatment:** Broad captured guides with1.5roof;2mm recessed ear floors; hard seats;0.3nominal guide gaps. Recessed M2x6 pan heads.

**Verification:** Static/35-motion checks; screw-head and battery/mic checks; all positive stop/capture witnesses.

**Remaining test:** Both keepers and P01 central stop must match stroke. Native combined audit plus measured guide return and service cycles.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_K01"></a>

## CTRL_K01 — Volume keeper roof, stop lands, screw ears and supporting floor

**Components:** K01, P02

**Concern:** Roof bending, stop fracture or seat damage

**Loading:** Edge press, hard press and screw tightening

**Evidence:** 5N at top cap edge gives10.92N guide reaction over4.35mm bearing span.

**Treatment:** Roof2.0; nominal floor1.7; broad stopwall and cap-face lands; screw hard seats.

**Verification:** 5N pre-stop roof/stem screens7.49/7.74MPa;10N stopped land screen7.47MPa; motion and stationary interface clear.

**Remaining test:** Actual material, local load distribution and deflection; pilot coupon then10 service/1000 actuations.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_K02"></a>

## CTRL_K02 — Volume keeper roof, stop lands, screw ears and supporting floor

**Components:** K02, P02

**Concern:** Roof bending, stop fracture or seat damage

**Loading:** Edge press, hard press and screw tightening

**Evidence:** 5N at top cap edge gives10.92N guide reaction over4.35mm bearing span.

**Treatment:** Roof2.0; nominal floor1.7; broad stopwall and cap-face lands; screw hard seats.

**Verification:** 5N pre-stop roof/stem screens7.49/7.74MPa;10N stopped land screen7.47MPa; motion and stationary interface clear.

**Remaining test:** Actual material, local load distribution and deflection; pilot coupon then10 service/1000 actuations.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_RECEIVERS"></a>

## CTRL_RECEIVERS — Guide bases, joint roots and preserved outer skin

**Components:** P01, P02, all control ADD/CUT/RESTORE masks

**Concern:** Receiver fracture, residual wall damage or exterior changes

**Loading:** Press loads, screw preload, case opening

**Evidence:** Exact original trimmed skins needed because nominal rounded apertures did not reproduce master outer trims.

**Treatment:** Exact original skin restoration after relief; new keepers trimmed0.3 farther inward. Broad seated guides and direct play/PTT stops.

**Verification:** One-solid review shells; exact outside-face audit; bounded topology heals logged.

**Remaining test:** Root combined exterior, closure and all-pair checks; physical service test. Backed skin patches are not generic minimum wall recommendations.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_PTT_CENTRE"></a>

## CTRL_PTT_CENTRE — Central bridge, flanking pillars and pad seat

**Components:** P01, P02, PTT keeper pad

**Concern:** Centre skin flexure adds travel beyond end stops

**Loading:** Hard press after nominal stroke

**Evidence:** End-only actual-section screen predicted up to0.47mm at10N.

**Treatment:** Fixed P01 bridge contacts lower backing at0.45; P02 relief permits it. TopZ−12.7 retains original pad support datum. Side pillars bypass switch/cradle for hard-stop force.

**Verification:** Default static/motion, positive0.46mm witness; actual section after-stop spans and bridge load screen.

**Remaining test:** Measure remaining local cap/receiver compliance against actual permitted switch travel; alternate stroke requires matched P01.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_K01_M2x6_PAN_1_REFERENCE"></a>

## CTRL_HC_K01_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_K01_M2x6_PAN_1_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_K01_M2x6_PAN_2_REFERENCE"></a>

## CTRL_HC_K01_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_K01_M2x6_PAN_2_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_K02_M2x6_PAN_1_REFERENCE"></a>

## CTRL_HC_K02_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_K02_M2x6_PAN_1_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_K02_M2x6_PAN_2_REFERENCE"></a>

## CTRL_HC_K02_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_K02_M2x6_PAN_2_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_P17_M2x6_PAN_1_REFERENCE"></a>

## CTRL_HC_P17_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_P17_M2x6_PAN_1_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_P17_M2x6_PAN_2_REFERENCE"></a>

## CTRL_HC_P17_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_P17_M2x6_PAN_2_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_P18_M2x6_PAN_1_REFERENCE"></a>

## CTRL_HC_P18_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_P18_M2x6_PAN_1_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_HC_P18_M2x6_PAN_2_REFERENCE"></a>

## CTRL_HC_P18_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach

**Components:** HC_P18_M2x6_PAN_2_REFERENCE

**Concern:** Pilot stripping, split boss or head collision

**Loading:** Tightening and10 service cycles

**Evidence:** Conservative pan headØ4x1.6; threads omitted from model.

**Treatment:** All8new keeper screws M2x6;Ø1.8pilots andØ2.2clearance; hard seats.

**Verification:** Head envelopes clear; intentional pilot engagement excluded.

**Remaining test:** Actual screw/process pilot coupon and torque-to-seat; no torque rating asserted.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_QC01_VOLUME_RECEIVER_PROCESS_COUPON"></a>

## CTRL_QC01_VOLUME_RECEIVER_PROCESS_COUPON — Process coupon contacts

**Components:** QC01_VOLUME_RECEIVER_PROCESS_COUPON

**Concern:** False confidence from different process or incomplete scope

**Loading:** Print qualification

**Evidence:** Exact receiver geometry on test foundation;6pilot diameters,7mm depth.

**Treatment:** QC01volume;QC02lower PTTstation;QC03pilots.

**Verification:** Valid STEP and explicit mapping in control_coupons.json.

**Remaining test:** Same material/orientation/postprocessing; coupons do not prove full PTTalignment or endurance.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_QC02_PTT_RECEIVER_PROCESS_COUPON"></a>

## CTRL_QC02_PTT_RECEIVER_PROCESS_COUPON — Process coupon contacts

**Components:** QC02_PTT_RECEIVER_PROCESS_COUPON

**Concern:** False confidence from different process or incomplete scope

**Loading:** Print qualification

**Evidence:** Exact receiver geometry on test foundation;6pilot diameters,7mm depth.

**Treatment:** QC01volume;QC02lower PTTstation;QC03pilots.

**Verification:** Valid STEP and explicit mapping in control_coupons.json.

**Remaining test:** Same material/orientation/postprocessing; coupons do not prove full PTTalignment or endurance.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_QC03_SCREW_PILOT_COUPON"></a>

## CTRL_QC03_SCREW_PILOT_COUPON — Process coupon contacts

**Components:** QC03_SCREW_PILOT_COUPON

**Concern:** False confidence from different process or incomplete scope

**Loading:** Print qualification

**Evidence:** Exact receiver geometry on test foundation;6pilot diameters,7mm depth.

**Treatment:** QC01volume;QC02lower PTTstation;QC03pilots.

**Verification:** Valid STEP and explicit mapping in control_coupons.json.

**Remaining test:** Same material/orientation/postprocessing; coupons do not prove full PTTalignment or endurance.

**Status:** CAD revised; physical qualification pending

<a id="risk-CTRL_PADS_RETURN"></a>

## CTRL_PADS_RETURN — Actual switches, rest gap, pad compression and return

**Components:** P03, P05, P06, P07, P04, P08, P09, P10, contact pads, rear keeper pads

**Concern:** No click, preload, sticking, coupled controls or overtravel

**Loading:** Normal presses, hard stops and tolerance stack

**Evidence:** Source switches are NOMINAL/NOT_OEM; inherited gap≈0.15mm and travel assumptions unmeasured.

**Treatment:** Contact datums preserved; default side0.45 and play0.50. Volume keeper alternatives0.30/0.40/0.50/0.60; PTT alternates require matched P01.

**Verification:** Geometric travel/capture proof only; no physical electrical or force test.

**Remaining test:** Follow CONTROLS.md measurement procedure, select shortest reliable travel, verify return and elastic overtravel, then10 service and1000 actuation cycles/control.

**Status:** CAD revised; physical qualification pending

<a id="risk-FX-P15"></a>

## FX-P15 — Lower antenna frame, X±17,Y−36.5..−27.5

**Components:** P15, original nylon antenna hardware

**Concern:** Original narrow bridge and thin seats can bend or split; bottoming/preload can overload the antenna flex.

**Loading:** Screw tightening, handling and5N service load

**Evidence:** Measured revised9×2.2mm span;Ø2.3 clearance holes;1.2mm locally relieved seats and minimum1.85mm radial stock. Original M2×3 nylon hardware retained.

**Treatment:** Broad clamp over four compliant contact locations, PET carrier and controlled pilot floor; original coax rerouted clear of clamp.

**Verification:** Valid STEP; simple5N span screening4.82MPa under stated hypothetical isotropic material; QF02 with actual P15.

**Remaining test:** Print/cure/orientation and nylon screw torque/strip/bottoming, pad compression and10cycles must be tested.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-P16"></a>

## FX-P16 — Upper antenna frame,Y57..67

**Components:** P16, original nylon antenna hardware

**Concern:** Thin cable bridge/ear bending or antenna preload can crack a printed frame.

**Loading:** Handling, clamp preload, cable snag

**Evidence:** Revised10×2.2mm main section,1.2mm local seats,Ø2.3 bores with minimum2.05mm radial ear stock.

**Treatment:** Broad end clamp without an enclosed fragile cable bridge; route and strap take cable loads separately.

**Verification:** Valid STEP; simple5N span screening4.34MPa under hypothetical isotropic assumptions; QF02 plus actual P16.

**Remaining test:** Actual printed part, layer/cure strength, nylon fastener preload and pad force remain unverified.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-REAR-BED"></a>

## FX-REAR-BED — X±11.25,Y−35.5..62.5,Z−22.10; four nylon pilots

**Components:** P02 antenna bed, P02 pilot floors, P02

**Concern:** Broad skin recess lowers stiffness; pilot floor or edge may split if screws bottom.

**Loading:** External handling, screw installation, closure pressure

**Evidence:** Nominal broad skin2.2→1.9mm; plate-thickness stiffness scaling0.644; local pilot-floor axial skin1.25mm. Nylon tip−22.13 vs floor−22.75 gives0.62mm tip clearance.

**Treatment:** Bounded0.30mm internal recess, separate PET dielectric; keep original outer geometry.

**Verification:** Non-destructive valid Booleans and root exterior proof; QF02 reproduces nominal bed/pilot geometry.

**Remaining test:** Thickness/impact and screw-coupon proof in actual production material; no universal process guarantee.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-ANT-RF"></a>

## FX-ANT-RF — Rear central antenna footprint

**Components:** original Taoglas FXUB63 antenna, maximum battery, PCB electronics

**Concern:** Detuning and efficiency loss despite mechanically clear surfaces.

**Loading:** Powered radio operation

**Evidence:** Antenna-to-maximum-battery planar gap5.15mm and PCB rear-plane gap7.4485mm are below Taoglas10mm minimum metal recommendation; components can be closer.

**Treatment:** Retain nylon hardware and dielectric; explicitly preserve RF qualification limit.

**Verification:** Nominal coordinates checked; no RF test or full conductive-field model.

**Remaining test:** Actual-device antenna matching/efficiency/radiated qualification.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-K03"></a>

## FX-K03 — X~14.4..29.6,Y−12.3..0,Z−10.55..−2

**Components:** K03 cover, P01 adapter cradle, extra B2B-PH header, passive FR4 carrier, K03, P01

**Concern:** Mating forces, solder-joint fatigue, printed root/cover fracture or wire pullout.

**Loading:** Factory plug mating/unmating and pigtail service pull

**Evidence:** Carrier8×6×1mm; four installed0.25mm edge pads; broad cover bridge1.8mm and side arms≥2.2mm. Dedicated outgoing insulated-wire grommet.

**Treatment:** Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.

**Verification:** Valid individual solids and hardware envelope checks; QF01 reproduces cradle with actual K03.

**Remaining test:** Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.

**Status:** SUPERSEDED HISTORICAL RECORD — NOT SELECTED FOR ASSEMBLY

<a id="risk-FX-HA-1"></a>

## FX-HA-1 — Adapter transverse fastener axes

**Components:** R36_HA_ADAPTER_M2x6_PAN_1_ENVELOPE

**Concern:** Printed threads strip, root splits or screw bottoms before clamping.

**Loading:** Hand assembly and repeated service

**Evidence:** M2×6 pan maximum headØ4×1.6; nominal4.4mm material overlap with3.4mm design full-thread allowance after1mm lead/runout reserve,0.95mm tip margin,Ø1.7 pilot.

**Treatment:** Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.

**Verification:** Nominal geometry and QF01; screw envelope is not helical thread simulation.

**Remaining test:** Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.

**Status:** SUPERSEDED HISTORICAL RECORD — NOT SELECTED FOR ASSEMBLY

<a id="risk-FX-HA-2"></a>

## FX-HA-2 — Adapter transverse fastener axes

**Components:** R36_HA_ADAPTER_M2x6_PAN_2_ENVELOPE

**Concern:** Printed threads strip, root splits or screw bottoms before clamping.

**Loading:** Hand assembly and repeated service

**Evidence:** M2×6 pan maximum headØ4×1.6; nominal4.4mm material overlap with3.4mm design full-thread allowance after1mm lead/runout reserve,0.95mm tip margin,Ø1.7 pilot.

**Treatment:** Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.

**Verification:** Nominal geometry and QF01; screw envelope is not helical thread simulation.

**Remaining test:** Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.

**Status:** SUPERSEDED HISTORICAL RECORD — NOT SELECTED FOR ASSEMBLY

<a id="risk-FX-CK-J2"></a>

## FX-CK-J2 — Fixed original J2 header

**Components:** J2 CK socket, original J2 PH PCB header

**Concern:** Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current.

**Loading:** Mating, cable routing and electrical operation

**Evidence:** JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.

**Treatment:** Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.

**Verification:** Catalog dimensions and nominal external-envelope checks; mating-gauge overlap is intentional, not a removed header.

**Remaining test:** Actual sample mating, exit Z, contact engagement, pin1/net map, selected wire termination and load/current qualification.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-CK-J3"></a>

## FX-CK-J3 — Fixed original J3 header

**Components:** J3 CK socket, original J3 PH PCB header

**Concern:** Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current.

**Loading:** Mating, cable routing and electrical operation

**Evidence:** JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.

**Treatment:** Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.

**Verification:** Catalog dimensions and nominal external-envelope checks; mating-gauge overlap is intentional, not a removed header.

**Remaining test:** Actual sample mating, exit Z, contact engagement, pin1/net map, selected wire termination and load/current qualification.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-CK-J10"></a>

## FX-CK-J10 — Fixed original J10 header

**Components:** J10 CK socket, original J10 PH PCB header

**Concern:** Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current.

**Loading:** Mating, cable routing and electrical operation

**Evidence:** JST catalog explicitly supports PH mating;6.9mm mounted height and maximum OD1.05 wire envelope. Socket cavity/pin details are not OEM STEP.

**Treatment:** Use matching normal/reverse cable-side CK variant, approved UL1061/UL10272 wire; keep original PCB header.

**Verification:** Catalog dimensions and nominal external-envelope checks; mating-gauge overlap is intentional, not a removed header.

**Remaining test:** Actual sample mating, exit Z, contact engagement, pin1/net map, selected wire termination and load/current qualification.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-PH-J8"></a>

## FX-PH-J8 — Original side-entry J8

**Components:** J8 PHR4, four PH crimp contacts

**Concern:** Plug housing or wire exit can hit wall; crimp pull can load header solder.

**Loading:** Mating and service cable pull

**Evidence:** Catalog6.85mm housing length/4.5mm depth, unchanged header pose; four OD1.05 selected routes.

**Treatment:** Ordinary PH plug retained; bound housing gauge and route; pair with final mechanical restraint.

**Verification:** Nominal route and catalog external gauge; gauge overlaps own mating header intentionally.

**Remaining test:** Actual housing/crimp/exit and pull restraint; connector catalog geometry is not production tolerance proof.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-LED-JOINTS"></a>

## FX-LED-JOINTS — Four distal LED leads at1.27mm pitch

**Components:** LED insulated joint1, LED insulated joint2, LED insulated joint3, LED insulated joint4

**Concern:** Oversized solder/insulation sleeves crowd neighboring legs and cause bending or shorts.

**Loading:** Harness dressing and service vibration

**Evidence:** Each final joint reserve is maximumØ1.15×3mm including insulation; nominal separation0.12mm. EarlierØ1.7 candidate failed and is not released.

**Treatment:** Use a measured small lap joint with qualified thin individual insulation; no solder bulge outside envelope, preserve original lead/body pose.

**Verification:** Four bounded joint envelopes and all-pair checks; intentional overlap only with own original LED lead.

**Remaining test:** Fabricated joint profile, insulation integrity and pull inspection; if infeasible, redesign distal forming/joint layout rather than force fit.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-SPK-LEADS"></a>

## FX-SPK-LEADS — Left front harness and X−23.6/Y5..13, X−26.8/Y−5..3

**Components:** two shortened speaker factory leads, two staggered speaker lap splices

**Concern:** Speaker lead exit uncertainty, bulky splice or unsupported pull can break a lead or pinch it against a support.

**Loading:** Speaker assembly and service removal

**Evidence:** Stock speaker leads152±5mm; original reference lacks terminal exits. Candidate OD1.3 routes and maximumØ3.2×8 staggered sleeves.

**Treatment:** Shorten speaker leads as needed, connect to approved CK pigtails; keep protected battery leads untouched.

**Verification:** Nominal route and bounded splice checks; termination overlap inside sleeve is intentional.

**Remaining test:** Actual factory speaker exit/OD, sleeve insulation, strain restraint and required length plus termination allowance.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-BAT-LEADS"></a>

## FX-BAT-LEADS — Right keeper service opening and front speaker annulus

**Components:** two intact factory battery leads, factory battery PHR2 plug

**Concern:** Lead forced around screw head, sharp edge, insufficient length or pouch-tab pull.

**Loading:** Battery insertion, closure and service

**Evidence:** Two100mm OD1.5 nominal curves preserve old CAD assumption; actual free length/OD/exit was not measured. R3.75 is an engineering assumption.

**Treatment:** Preserve factory cable and plug; nested slack paths and explicit screw/keeper relief, remote captured passive adapter.

**Verification:** Nominal100mm length, swept route validity, max-body and control checks; exact physical lead qualification separate.

**Remaining test:** Measure received free cable and protected tab; verify bend/slack/dressing with no pouch pressure or tension. Never cut/solder battery assembly to match a drawing.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-MIC-WINDOW"></a>

## FX-MIC-WINDOW — Left wall nearY−28..−22

**Components:** P01 microphone wire window, P02 microphone wire window, P01, P02

**Concern:** Several close round bores leave thin fins or sever a PCB/guide support.

**Loading:** Wire insertion and shell handling

**Evidence:** Joined rounded front/rear windows replace adjacent close grooves; front nominal retained web≥6.3mm.

**Treatment:** Open broad window, no P13 terminal drilling; root-integrated support geometry is checked separately.

**Verification:** Valid Boolean and full-shell volume/continuity/exterior checks.

**Remaining test:** Actual edge finish and print strength, no hidden sharp edge or wire rubbing.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-MIC-SADDLE"></a>

## FX-MIC-SADDLE — X−21.5..−15.5,Y−33..−17

**Components:** P01 integral mic saddle, mic silicone facing, mic polyester strap, P01

**Concern:** Adhesive peel, wire slip or saddle break lets pull reach microphone/PCB joints.

**Loading:** 5N service pull and repeated assembly

**Evidence:** 6×16mm broad saddle,0.25mm installed silicone and0.10mm tape; two2mm bond lands.

**Treatment:** Route five wires over compliant facing and bond replaceable strap; keep new play bars clear.

**Verification:** Valid geometry, intended wire/pad and tape contacts; QF03 test base.

**Remaining test:** Tape/print-surface adhesion after cure and temperature exposure, grip and10service cycles; no adhesive rating inferred.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-COAX"></a>

## FX-COAX — New right-side rear route

**Components:** original150mm coax, fixed original J5 plug, two formed nonconductive silicone tacks

**Concern:** Cable bend/abrasion or unretained loop pulls RF connector or antenna feed.

**Loading:** Assembly and service handling

**Evidence:** Explicit150mm centerline,Ø1.37 actual cable gauge, R5 and feed coordinate are assumptions; larger clearance envelope and two4mm-long formed silicone tacks.

**Treatment:** Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.

**Verification:** Nominal sweep, paired shell channels and intentional plug termination; no cable fatigue or RF test.

**Remaining test:** Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.

**Status:** SUPERSEDED HISTORICAL RECORD — NOT SELECTED FOR ASSEMBLY

<a id="risk-FX-J8-SADDLE"></a>

## FX-J8-SADDLE — X15.5..18.8,Y−42.5..−26.2

**Components:** P01 J8 saddle, J8 silicone facing, J8 polyester strap, P01

**Concern:** Adhesive peel or bundle slip passes load to the PH header or LED legs; a crossing control wire can be pinched.

**Loading:** Cable insertion,5N service pull and closure

**Evidence:** Broad integral support with4/3.3mm tape bond lands,24.09mm² total nominal bond area;0.25mm silicone and0.10mm tape.Ø1.85 rear-open passage preserves J9 pin1 atY−35/Z−9.7.

**Treatment:** Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.

**Verification:** Valid solids and intended contacts; QF04 exact geometry coupon and combined J9 check.

**Remaining test:** Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.

**Status:** SUPERSEDED HISTORICAL RECORD — NOT SELECTED FOR ASSEMBLY

<a id="risk-FX-STOCK-R36_STOCK_ANTENNA_CARRIER_ADHESIVE_0p05"></a>

## FX-STOCK-R36_STOCK_ANTENNA_CARRIER_ADHESIVE_0p05 — [[-10.2, -34.2, -22.1], [10.2, 61.2, -22.05]]

**Components:** R36_STOCK_ANTENNA_CARRIER_ADHESIVE_0p05

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_1_INSTALLED_0p42"></a>

## FX-STOCK-R36_STOCK_ANTENNA_END_PAD_1_INSTALLED_0p42 — [[-9.5, -33.75, -21.75], [-4.5, -29.75, -21.33]]

**Components:** R36_STOCK_ANTENNA_END_PAD_1_INSTALLED_0p42

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_2_INSTALLED_0p42"></a>

## FX-STOCK-R36_STOCK_ANTENNA_END_PAD_2_INSTALLED_0p42 — [[4.5, -33.75, -21.75], [9.5, -29.75, -21.33]]

**Components:** R36_STOCK_ANTENNA_END_PAD_2_INSTALLED_0p42

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_3_INSTALLED_0p42"></a>

## FX-STOCK-R36_STOCK_ANTENNA_END_PAD_3_INSTALLED_0p42 — [[-9.5, 57.25, -21.75], [-4.5, 61.25, -21.33]]

**Components:** R36_STOCK_ANTENNA_END_PAD_3_INSTALLED_0p42

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_4_INSTALLED_0p42"></a>

## FX-STOCK-R36_STOCK_ANTENNA_END_PAD_4_INSTALLED_0p42 — [[4.5, 57.25, -21.75], [9.5, 61.25, -21.33]]

**Components:** R36_STOCK_ANTENNA_END_PAD_4_INSTALLED_0p42

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ANTENNA_PET_DIELECTRIC_0p10"></a>

## FX-STOCK-R36_STOCK_ANTENNA_PET_DIELECTRIC_0p10 — [[-10.2, -34.2, -22.05], [10.2, 61.2, -21.95]]

**Components:** R36_STOCK_ANTENNA_PET_DIELECTRIC_0p10

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25"></a>

## FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25 — [[18.0, -4.0, -10.3], [18.8, -3.75, -4.3]]

**Components:** R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25"></a>

## FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25 — [[18.0, -5.25, -10.3], [18.8, -5.0, -4.3]]

**Components:** R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25"></a>

## FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25 — [[25.2, -4.0, -10.3], [26.0, -3.75, -4.3]]

**Components:** R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25"></a>

## FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25 — [[25.2, -5.25, -10.3], [26.0, -5.0, -4.3]]

**Components:** R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED"></a>

## FX-STOCK-R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED — [[19.1, -12.3, -8.600000001016], [24.9, -10.3, -5.999999998983999]]

**Components:** R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=2.

**Treatment:** Cut/select measured stock; keep intended contact only and replace old stock, never stack.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Actual stock material/thickness, compression/adhesion and physical cycling are not established by CAD.

**Status:** NOMINAL_CAD_TREATMENT; PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_1_L4"></a>

## FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_1_L4 — [[30.149999899999997, -26.0000001, -22.085000100000002], [32.833986543971, -21.9999999, -19.649999899999997]]

**Components:** R36_STOCK_COAX_FORMED_SILICONE_TACK_1_L4

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.

**Status:** SUPERSEDED HISTORICAL RECORD — NOT SELECTED FOR ASSEMBLY

<a id="risk-FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_2_L4"></a>

## FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_2_L4 — [[30.15, -9.0, -22.085], [32.83398644397425, -5.0, -19.65]]

**Components:** R36_STOCK_COAX_FORMED_SILICONE_TACK_2_L4

**Concern:** Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip.

**Loading:** Assembly preload, temperature and service cycles

**Evidence:** Explicit installed envelope; valid=True, solids=1.

**Treatment:** Use the final correction register and Fixture_Final_Corrections.md. The earlier RTV tacks, flat J8 strap, Y-axis adapter, old hardware poses and untrimmed microphone facing are excluded; use Adapter_Final_Seat_and_Fasteners.md for the final adapter.

**Verification:** Nominal dimensional envelope and host contact check; linked QF01/QF02/QF03 as applicable.

**Remaining test:** Apply the selected final correction coupon and assembly protocol; this historical entry is not a physical pass.

**Status:** SUPERSEDED HISTORICAL RECORD — NOT SELECTED FOR ASSEMBLY

<a id="risk-FX-FINAL-J8-CORNER"></a>

## FX-FINAL-J8-CORNER — X15.4…18.9,Y−42.6…−40.6,Z−10.5…−7.79

**Components:** P01 J8 saddle, CUT_P01_J8_REAR_OPEN_J9_CORNER_FINAL, P01

**Concern:** J9 clearance sweep leaves0.65mm lip that can fracture or trap a control wire.

**Loading:** Assembly, cable pull, control service

**Evidence:** Rear-open corner removes lip; one connected saddle/root; finalwiregap0.5081mm.

**Treatment:** Open the back of the crossing and wrap strap onto retained vertical face.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Exact final shell/export andQF04B5Npull, tape peel and10servicecycles.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-J8-STRAP"></a>

## FX-FINAL-J8-STRAP — J8 saddle rear face and newY−40.6 end face

**Components:** R36_STOCK_J8_FORMED_END_WRAP_STRAP_0p10_FINAL

**Concern:** Insufficient bonded land or wire abrasion permits slip and loads solder joints.

**Loading:** 5Nservice pull and repeated assembly

**Evidence:** 26.3175mm² nominal contact:6.93lower+10.89upper+8.4975vertical; pin4gap0.3711mm.

**Treatment:** Form0.10mmmaximum polyester strap around end, apply only to clean qualified print lands; replace old strap.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Actual tape thickness/adhesion, fold radius, pull/slip,10cycles; do not stack oldstrap.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-COAX-STRAP-1"></a>

## FX-FINAL-COAX-STRAP-1 — Right rear cable runY−37…−33

**Components:** R36_STOCK_COAX_CURVED_LAND_STRAP_1_0p10_FINAL

**Concern:** Chemical bond to FEP is unreliable; flat tape contours enter curved wall; axial cable slip loads RF feed/plug.

**Loading:** Cable dressing and5Nservice screen

**Evidence:** PrimaryTaoglasFXUB63drawing namesFEP; selected feet conform to unchangedR7.8wall with16.765mm² conservative printed-land contact.

**Treatment:** WithdrawRTVtacks. Use mechanical tape/silicone clamp with printed-land adhesion; no FEP adhesive credit.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** QF05 actual printedfinish,tape,saddle andcoax: axial/lateral grip withoutcrush,kink,peel or electrical/impedance change; confirm actualbend limit.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-COAX-PAD-1"></a>

## FX-FINAL-COAX-PAD-1 — Under coax within existing clearance channel

**Components:** R36_STOCK_COAX_UNBONDED_HALF_SADDLE_1_0p40_INSTALLED

**Concern:** Pad too hard/thick crushes coax; too soft/thin loses preload and friction.

**Loading:** Strap installation, dwell, service pull

**Evidence:** 0.40mm radial installed half-saddle,0.45mmfree starting thickness; cable and shell contacts intentional.

**Treatment:** Use nonadhesive soft insulating silicone formed beneath cable, grade/compression chosen bycoupon.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Actual material, compression set, clamp preload and cable RF/electricalintegrity. No untesteddurometer/pressure prescribed.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-COAX-STRAP-2"></a>

## FX-FINAL-COAX-STRAP-2 — Right rear cable runY−22…−18

**Components:** R36_STOCK_COAX_CURVED_LAND_STRAP_2_0p10_FINAL

**Concern:** Chemical bond to FEP is unreliable; flat tape contours enter curved wall; axial cable slip loads RF feed/plug.

**Loading:** Cable dressing and5Nservice screen

**Evidence:** PrimaryTaoglasFXUB63drawing namesFEP; selected feet conform to unchangedR7.8wall with16.765mm² conservative printed-land contact.

**Treatment:** WithdrawRTVtacks. Use mechanical tape/silicone clamp with printed-land adhesion; no FEP adhesive credit.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** QF05 actual printedfinish,tape,saddle andcoax: axial/lateral grip withoutcrush,kink,peel or electrical/impedance change; confirm actualbend limit.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-COAX-PAD-2"></a>

## FX-FINAL-COAX-PAD-2 — Under coax within existing clearance channel

**Components:** R36_STOCK_COAX_UNBONDED_HALF_SADDLE_2_0p40_INSTALLED

**Concern:** Pad too hard/thick crushes coax; too soft/thin loses preload and friction.

**Loading:** Strap installation, dwell, service pull

**Evidence:** 0.40mm radial installed half-saddle,0.45mmfree starting thickness; cable and shell contacts intentional.

**Treatment:** Use nonadhesive soft insulating silicone formed beneath cable, grade/compression chosen bycoupon.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Actual material, compression set, clamp preload and cable RF/electricalintegrity. No untesteddurometer/pressure prescribed.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-SPEAKER-LEAD2"></a>

## FX-FINAL-SPEAKER-LEAD2 — Left front route withX−27.4,Y22…10,Z−8.9

**Components:** R36_SPEAKER_FACTORY_LEAD_2_J9_BYPASS_OD1p3_R3_FINAL

**Concern:** Factory lead crosses fixedPTTsignal/common wires or rubs new channel.

**Loading:** Speaker insertion/service

**Evidence:** 45.716mmcenterline,OD1.3,R3; factory assumedstart andfixedspliceend unchanged; localpaired0.4shellrelief.

**Treatment:** Route behind the fixedPTTjoints andretainfullfactory-insulationrun; cutonlyspeakerlead asqualified, neverbattery cable.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Receivedspeakerexit/diameter, actualroute+5mmterminationallowance, edgefinish/strainretention, finalJ9combinedcheck.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-SPEAKER-SLEEVE1"></a>

## FX-FINAL-SPEAKER-SLEEVE1 — X−23.6,Y5…13,Z−4.4

**Components:** R36_SPEAKER_LAP_SPLICE_1_FORWARD_0p30_FINAL

**Concern:** ClosePTTsignal adjacency or insufficient insulation creates rubbing/short risk.

**Loading:** Harness dressing andvibration

**Evidence:** FullØ3.2×8sleeve moves0.30forward; originalwireentries retainedwithinendsection, factoryradialreserve~0.279mm.

**Treatment:** Shift complete insulatedjointenvelope; addpaired0.4shellrelief, noinsulationtrimming.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Fabricatedjoint dimensions, requiredinsulationthickness/coverage andsliptest; sleeve is anenvelope not electricallyqualifiedconstruction.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-KEEPER-PORTS"></a>

## FX-FINAL-KEEPER-PORTS — Openwireports andupperanchor neckedges

**Components:** P19, P20

**Concern:** Clearance cuts might sever a narrow neck or screw-seat roof.

**Loading:** 5Nkeeper service andscrewpreload

**Evidence:** P19delta0.00223mm³,P20delta0.04410; spines4×2.3×3 and2.5×7×3 remain100%; conservative deep-neck screen6.98MPa using4.549mmwidth.

**Treatment:** Retainmainspines/seat; limitclearance to freeportedge and0.05083mmedgetrim.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** HypotheticalE1000MPa/allowable8MPa only; actualnotch/anisotropy/pilot/preload andservicecouponqualification.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-COUPON-QF04B_J8_REAR_OPEN_CORNER_AND_FORMED_STRAP_TEST_BASE"></a>

## FX-COUPON-QF04B_J8_REAR_OPEN_CORNER_AND_FORMED_STRAP_TEST_BASE — Testcoupon

**Components:** QF04B_J8_REAR_OPEN_CORNER_AND_FORMED_STRAP_TEST_BASE

**Concern:** Unrepresentativeprocess orsurfacefinish makes test misleading.

**Loading:** Firstarticle qualification

**Evidence:** Exactproductionfeaturecoupon, validSTEP/watertightSTL; no physicaltestdone.

**Treatment:** Printwithproductionorientation/material/finish; followcorrectionnotes.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Dimensions, grip, damageinspection andassemblycycling; passingcoupon doesnotcertifywholeproduct.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-COUPON-QF05_COAX_CURVED_LANDS_AND_CABLE_SADDLE_TEST_BASE"></a>

## FX-COUPON-QF05_COAX_CURVED_LANDS_AND_CABLE_SADDLE_TEST_BASE — Testcoupon

**Components:** QF05_COAX_CURVED_LANDS_AND_CABLE_SADDLE_TEST_BASE

**Concern:** Unrepresentativeprocess orsurfacefinish makes test misleading.

**Loading:** Firstarticle qualification

**Evidence:** Exactproductionfeaturecoupon, validSTEP/watertightSTL; no physicaltestdone.

**Treatment:** Printwithproductionorientation/material/finish; followcorrectionnotes.

**Verification:** Valid exact CAD, selected-obstacle checks and specified coupon only; physical testing not performed.

**Remaining test:** Dimensions, grip, damageinspection andassemblycycling; passingcoupon doesnotcertifywholeproduct.

**Status:** GEOMETRY_CHECKED_PHYSICAL_QUALIFICATION_OPEN

<a id="risk-FX-FINAL-BATTERY-INWARD-RISERS"></a>

## FX-FINAL-BATTERY-INWARD-RISERS — Right battery lead rise and keeper port, Y about39…46mm

**Components:** P01, P20, R36_FACTORY_BATTERY_LEAD_1_100mm_INWARD_RISER_FINAL, R36_FACTORY_BATTERY_LEAD_2_100mm_INWARD_RISER_FINAL

**Concern:** Outer wire-clearance sweep breached the fixed curved front exterior; inward reroute can pinch a wire against a head or weaken its keeper port.

**Loading:** Battery insertion, hand closure and service cable dressing

**Evidence:** OriginalCUT_ROUTE15 removed3.08277mm² of outerface. Replacement100mm routes have0.20mm pairgap; exact newchannel-face-to-originaloutside minima1.74808mm and0.999932mm. No originalpatch/classifiedouterarea intersection. NewP20cut2.11862mm³ leaves full2.5×7×3mm spine and removes0stockfrom bothanchor necks.

**Treatment:** Rebuild omittingoldfactorywire14/15masks. Installpaired inwardrisers with matchednewclearance; preservefactorystart,plugend,insulation,tabprotection andmodeled100mm length. Do notrestoreoutsidebyaddingstockoverwire.

**Verification:** ValidBRep, explicitmaskmapping, selectedhardware/currentJ9pairchecks and sourceouterface measurements; completefinalintegratedexteriorproof remainsroot-owned.

**Remaining test:** Actual100mmfactorylead availability/OD/tabdress, printdistortion, local~1mmcurvedskin handling, keeper free-portcorner andcompleteclosure/service tests. No physicalpass claimed. Support the keeper during support removal and feed wires gently; no levering on the1.336mm free-port shelf.

**Status:** CAD CANDIDATE CHECKED; FINAL INTEGRATION AND PHYSICAL QUALIFICATION REQUIRED

<a id="risk-FX-ADAPTER-FINAL-BASE"></a>

## FX-ADAPTER-FINAL-BASE — Adapter seat and two rear-access receiver posts

**Components:** P01, ADD_P01_ADAPTER_FULL_CLEARANCE_SUPPORTED_SEAT_FINAL

**Concern:** Old roots overlapped the carrier and all four pads. Simply widening the old pocket would leave a 0.05 mm pilot wall. Wire relief can also weaken a receiver.

**Loading:** Carrier insertion, connector mating, tapping, cable pull and service

**Evidence:** Full original-host replay is valid one solid after every operation. Carrier gap 0.25 mm; lateral/end allowance 0.30 mm; header gap 0.399 mm. Final pilot-to-wire ligaments 1.20548 mm left and 0.96161 mm right; right carrier-side minimum 0.95 mm. Pilot-floor to original outside 1.8999 mm.

**Treatment:** Replace the old base and Y-axis pilots. Use rear-access posts with controlled M2 tapping and full supported cover seats. The CK2 manufactured front lane moves 1 mm inboard; J9 and factory battery leads remain fixed.

**Verification:** Actual sliced post sections: minimum areas 15.239/14.503 mm², isolated-post 5 N bending screen 1.99/2.20 MPa under hypothetical 8 MPa allowance. QF01B reproduces the channels. These are not measured material capacities.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-ADAPTER-FINAL-COVER"></a>

## FX-ADAPTER-FINAL-COVER — Rear-access cover, grommet webs and 2 mm screw ears

**Components:** K03

**Concern:** A screw head inside an old grommet web prevents assembly; cutting away head support can leave a fragile cover.

**Loading:** Tightening, wire grip, connector pull and installation

**Evidence:** Final cover 580eec is valid one solid; full host, corrected carrier, pads, screws and termination are clear. Ear thickness 2 mm. Lower/upper rail minima 2.025/2.14 mm over 6 mm depth; independent rails receive 10 N screen. Corrected insulation clearance 0.36 mm.

**Treatment:** Use final termination-clearance cover and preassemble the complete carrier/header/insulation/pad/grommet module outside the shell. Insert from open rear before PCB and dress the flexible lead afterward. The cover-only path past fixed solder joints is unsuitable.

**Verification:** Nine preassembled rear insertion positions pass nominal geometry; rear driver access requires PCB/module removal. Independent rail and longitudinal-web screens peak 7.28 MPa under hypothetical 8 MPa with 2×nominal-stress factor. These do not qualify actual printed strength, fatigue or tapping.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-ADAPTER-FINAL-SCREW-1"></a>

## FX-ADAPTER-FINAL-SCREW-1 — Adapter screw axis X15.6, Y−6.05

**Components:** R36_HA_ADAPTER_M2x6_PAN_1_REAR_ACCESS_FINAL

**Concern:** Pilot cracking, thread strip, bottoming or crushed carrier pads from uncontrolled tightening.

**Loading:** Assembly tightening and repeated removal

**Evidence:** M2×6 pan envelope 4×1.6 mm; headZ−10.1…−8.5, cover seat−6.5, point−2.5, pilot floor−1.9. Nominal material engagement 4.0 mm; design full-thread allowance 3.0 mm after 1.0 mm tip/runout reserve. Point clearance 0.60 mm.

**Treatment:** Machine screw in a controlled hand-tapped M2×0.4 pilot, not a forced self-tapping installation. Set torque through coupon strip/seat tests.

**Verification:** Full head/shaft clears actual retained electronics and new routes. Right head-to-rear soft pad minimum 0.2472 mm. Dimensions remain purchased-hardware qualification gates.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-ADAPTER-FINAL-SCREW-2"></a>

## FX-ADAPTER-FINAL-SCREW-2 — Adapter screw axis X28.1, Y−6.05

**Components:** R36_HA_ADAPTER_M2x6_PAN_2_REAR_ACCESS_FINAL

**Concern:** Pilot cracking, thread strip, bottoming or crushed carrier pads from uncontrolled tightening.

**Loading:** Assembly tightening and repeated removal

**Evidence:** M2×6 pan envelope 4×1.6 mm; headZ−10.1…−8.5, cover seat−6.5, point−2.5, pilot floor−1.9. Nominal material engagement 4.0 mm; design full-thread allowance 3.0 mm after 1.0 mm tip/runout reserve. Point clearance 0.60 mm.

**Treatment:** Machine screw in a controlled hand-tapped M2×0.4 pilot, not a forced self-tapping installation. Set torque through coupon strip/seat tests.

**Verification:** Full head/shaft clears actual retained electronics and new routes. Right head-to-rear soft pad minimum 0.2472 mm. Dimensions remain purchased-hardware qualification gates.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-ADAPTER-FINAL-PAD-LANDS"></a>

## FX-ADAPTER-FINAL-PAD-LANDS — Four carrier edge pads and front backing columns

**Components:** R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25, R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25, R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25, R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25

**Concern:** Thin unsupported ledges bend; excessive pad compression or misassembly loads the carrier/header pins.

**Loading:** Mating/pull load and cover tightening

**Evidence:** Front support is 2.8×3.0 mm; 0.6 of each 0.8 mm pad width is supported, giving 3.6 mm² contact per front pad. Unbacked outer 0.2 mm is soft pad only. Rear pads retain cover contact.

**Treatment:** Seat the carrier/pads before the cover. The cover closes onto hard supports; it must not be tightened to force a warped carrier into place.

**Verification:** Conservative 5 N end load on one 6.6 mm backing gives 7.86 MPa under hypothetical 8 MPa allowance. Actual pad grip/compression remains a physical test.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-ADAPTER-FINAL-GROMMET"></a>

## FX-ADAPTER-FINAL-GROMMET — Outgoing insulated CK pair at K03

**Components:** R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED

**Concern:** Cable pull reaching solder joints, insulation abrasion or silicone slip.

**Loading:** Cable dressing and 5 N service pull

**Evidence:** Final cover preserves the split-grommet pose and cable endpoints. Corrected termination clears grommet 0.3414 mm and final cover 0.36 mm. Its load is retained through grommet and reinforced rails, not contact against insulation.

**Treatment:** Use the specified installed split grommet around intact insulation and close the matching cover before loading the cable.

**Verification:** Nominal full-assembly clearance and QF01B mating geometry checked; grip, creep and jacket damage have not been tested.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-ADAPTER-FINAL-CK2"></a>

## FX-ADAPTER-FINAL-CK2 — Manufactured CK2 front lane

**Components:** R36_J2_CK_PIGTAIL_2_ADAPTER_LIGAMENT_FINAL

**Concern:** A channel too close to the pilot leaves a thin torque-loaded wall; poor wire dressing can rub or pull contacts.

**Loading:** Assembly and service motion

**Evidence:** Only the front lane moved 1 mm inboard. Endpoints and R3/OD1.05 mm routing assumptions remain. Left pilot-channel ligament grows 0.404→1.20548 mm. No new checked reference collision.

**Treatment:** Install the selected final route and replacement clearance mask; do not retain the old CK2 reference or stack both routes.

**Verification:** Full P01 replay and loaded current-reference audit pass. Wire-to-own CK/header mating geometry is intentionally classified separately; bend rating, polarity and IDC connection remain hardware gates.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-ADAPTER-FINAL-COUPON"></a>

## FX-ADAPTER-FINAL-COUPON — Qualification coupon

**Components:** QF01B_REAR_ACCESS_ADAPTER_ACTUAL_SEAT_AND_WIRE_RELIEF

**Concern:** A generic post coupon can miss the final thin ligaments, pad/backer geometry and wire channels.

**Loading:** Print qualification before first assembled article

**Evidence:** QF01B is cropped from the actual final P01 after all wire cuts, with both rear pilots, floor skins and carrier lands. STEP one solid; STL watertight and consistent.

**Treatment:** Replace old Y-axis QF01. Use actual final K03, corrected carrier, pads, grommet and purchased screws as mating pieces.

**Verification:** No coupon was printed or loaded. This is a test fixture, not evidence of physical performance.

**Remaining test:** Qualify actual material, orientation, tapping, screw dimensions and torque on QF01B, then 5 N separate plug/cable pulls and ten service cycles. No physical pass is recorded.

**Status:** NOMINAL CAD CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-FX-MIC-FACING-FINAL"></a>

## FX-MIC-FACING-FINAL — Microphone facing at X−21.5…−15.5, Y−30…−19.5, Z−8.975…−8.725

**Components:** R36_STOCK_MIC_SADDLE_SILICONE_TRIMMED_6x10p5x0p25_FINAL, R36_STOCK_MIC_SADDLE_POLYESTER_STRAP_0p10, P01 microphone harness saddle, P01

**Concern:** The original facing overlapped the rising formed strap by 0.147692 mm³, risking a folded edge, uncontrolled preload or strap lift.

**Loading:** Tape application, cable dressing and microphone bundle pull

**Evidence:** Upper facing edge shortened by 0.50 mm. New facing is 6.0 × 10.5 × 0.25 mm, retaining 63/66 mm² (95.45%). Strap overlap is zero; minimum normal gap is 0.121268 mm. All five original wire contact rows remain supported; upper edge extends 0.965 mm beyond the last wire surface.

**Treatment:** Replace only the silicone facing with the trimmed stock. Keep the existing shell saddle, formed strap and both 2 mm printed bond lands. No material interpenetration or compression is credited at the ramp.

**Verification:** Valid one-solid replacement STEP; exact strap and all five wire contact checks. The new solid is wholly inside the original facing. QF03 geometry remains applicable with this trimmed stock.

**Remaining test:** Verify installed 0.25 mm thickness and edge placement, adhesive bond and jacket contact on QF03. Apply 5 N bundle pull and ten service cycles; reject lift, slip, damage or rubbing. No physical test was performed.

**Status:** NOMINAL STOCK FIT CHECKED; PHYSICAL QUALIFICATION OPEN

<a id="risk-J9-ROUTES"></a>

## J9-ROUTES — Original side-entryJ9 to the four unchanged switch locations

**Components:** J9 PHR-5, five connector leads, three common links, short upper-volume pigtail

**Concern:** Wire pinch, scraping, sharp bends or cable forces transmitted to connector/solder joints.

**Loading:** Assembly, control presses and opening/service.

**Evidence:** Nine OD1.05mm wire solids with R3 static bends; fixed PHR5 gauge6.85×11.8×4.5mm. Exact route metadata and all cut lengths are recorded.

**Treatment:** Keep fixed header/PCB positions. Route around locating stock and controls. Common-return chain removes the large central junction.

**Verification:** j9_final_verification.json; source routes; original header overlap classified as intentional mating.

**Remaining test:** Confirm received latch/exit geometry, selected wireOD≤1.05, static bend suitability, actual routing and connector-body access. Do not force a connector or wire into position.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-SHELLS"></a>

## J9-SHELLS — Local cable channels and terminal pockets

**Components:** P01, P02

**Concern:** Internal relief removes load-bearing stock or changes the locked exterior.

**Loading:** Shell closure and fastener loads.

**Evidence:** Wire clearanceØ1.65 gives0.30mm radial allowance. The outboardP01 lane reachesX31.075, preserving the retained locating core throughX30.8 with0.275mm separation.

**Treatment:** Cut exact routed sweeps only, after all shell additions. Preserve core/contact faces. Add matching wire supports.

**Verification:** Valid one-solid trials; per-cut volume/bounds and original-outer-face distances in j9_shell_mask_audit.json.

**Remaining test:** Root exact exterior/seam proof, full native assembly and load-path review of the smallP02 exit notches. First-article wall/fit checks remain required.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-TERMINALS"></a>

## J9-TERMINALS — Nominal switch legs

**Components:** ten insulated terminal joints, four original switches

**Concern:** Bare solder, wrong contact pairing, oversized sleeves, or bending a terminal against a printed cradle.

**Loading:** Soldering, wire dressing and control operation.

**Evidence:** Original switch geometry is explicitly non-OEM nominal. Joint envelopesØ1.5×2.0–3.2mm overlap only intended tabs; play approaches use existing X-direction access.

**Treatment:** One wire per used switch leg. Fully insulate exposed conductor and solder. Preserve switch body/seat positions.

**Verification:** Exact CAD intersections and named joint/terminal poses; P04 needs no additional cut.

**Remaining test:** Verify actual switch legs and same-contact pairs by continuity, confirm J9 PCB net mapping, qualify solder/insulation and inspect for shorts before power. Geometric pin-row labels are not a verified electrical pinout.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-COMMON-JUNCTION"></a>

## J9-COMMON-JUNCTION — X17…23,Y23.4,Z−11.25

**Components:** upper-volume common junction, short pigtail

**Concern:** A bulky or exposed branch joint collides with PCB, battery toe or control guide.

**Loading:** Harness assembly and service pull.

**Evidence:** One fully insulated three-way junction has maximumØ2.4×6mm; straight short pigtail≈7.489mm links the original rear-common terminal.

**Treatment:** Keep the junction in its defined saddle and within the sleeve envelope. Two common links meet inside this sleeve; no naked crossing is allowed.

**Verification:** Junction/PCB nominal gap0.5215mm before tape; exact intersection outside sleeve is checked.

**Remaining test:** Qualified joint fabrication and insulation coverage. Validate actual sleeve dimensions and strain relief with a gentle pull and operation test.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-PTT-SUPPORT"></a>

## J9-PTT-SUPPORT — X−25.5…−20.5,Y−15.5…−12.5

**Components:** P01 PTT wire support, PTT signal, PTT common return, P01

**Concern:** Support splitting or an unremovable wire forced through a printed passage.

**Loading:** Wire insertion and service loads.

**Evidence:** Upper nominalØ1.65 bore; lowerØ1.65 rear-open channel; side ligaments1.675mm.

**Treatment:** Broad front-rooted support. Feed the upper signal before terminal soldering; lay lower return in the open channel. The harness stays on the front shell during ordinary service.

**Verification:** Valid support; matched routed clearance; QJ01 exact support coupon. Hypothetical5N root gross stress≈6.37MPa and one-side local strip≈7.86MPa versus assumed8MPa, not material certification.

**Remaining test:** Actual process coupon, no forced insertion,5N retention screen and10service cycles. Check bore/root stress concentrations and actual material direction/creep.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-PTT-TAPE"></a>

## J9-PTT-TAPE — 5×3×0.10mm installed rear strip

**Components:** PTT rear retaining tape

**Concern:** Adhesive peels and the return leaves its groove.

**Loading:** Service handling and cable movement.

**Evidence:** Two rear lands total≈10.05mm²;0.10mm installed insulating polyester strip.

**Treatment:** Use compatible tape, clean printed lands, replace after opening. Grip connector housings and support wires during service.

**Verification:** Exact tape envelope clear of hardware; actual adhesion is untested.

**Remaining test:** Require5N tape/support coupon screen and10service cycles on the actual print material. Average5N/land area≈0.50MPa is only a load calculation; no tape strength is assumed. Hold release if peeling occurs.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-JUNCTION-SUPPORT"></a>

## J9-JUNCTION-SUPPORT — Shelf X17…29.5,Y18.5…24.8; root X25…29.5,Y14.5…18.5

**Components:** P01 common-junction support, silicone facing, P01

**Concern:** Unsupported splice bends solder joints or support interferes with nearby wiring.

**Loading:** Wire dressing and service pull.

**Evidence:** Support has a 3×1.2 mm through-slot in a 2.15 mm shelf, with a 1.85 mm local pad seat. It joins the retained PCB backing4. Facing3.5×0.8×0.30 mm installed, including adhesive.

**Treatment:** Outboard front root and broad shelf below the factory-wire plane; matched wire relief. Soft facing cushions the insulated joint. PCB contact stock is preserved.

**Verification:** Valid support and complete fixture-reference checks; QJ02 includes the actual retained PCB backing. See j9_junction_load_screen.json for gross section calculations and the unqualified torsion/notch limit.

**Remaining test:** Physical support/film fit, no exposed solder, no adhesive contamination and5N/10cycle retention check. Beam numbers exclude notch, material anisotropy and creep.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-JUNCTION-LOOP"></a>

## J9-JUNCTION-LOOP — 2.5mm wide loop through the support slot

**Components:** insulating polyester loop

**Concern:** Loop loosens or adhesive fails, loading the three-way joint.

**Loading:** Service pull and vibration.

**Evidence:** 0.10mm installed tape; initial2.5×40mm stock,≥10mm self-bond overlap. Routed loop clears the battery toe by≈0.408 mm and the intact factory leads by at least≈0.35 mm; short-pigtail gap≈0.183 mm is a tight dressing gate.

**Treatment:** Thread through fixed slot and wrap the insulated junction; snug only, without pulling solder joints. Replace after service.

**Verification:** Actual CAD envelope and qualified coupon method; adhesion not physically tested.

**Remaining test:** Verify folded thickness, no pinch,≥10mm overlap and5N pull on actual tape/material. Do not interpret the model as supplier tape qualification.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-COUPONS"></a>

## J9-COUPONS — Standalone exact-support print coupons

**Components:** QJ01, QJ02

**Concern:** A failed print process is used directly in the complete shell.

**Loading:** Pilot printing and assembly qualification.

**Evidence:** Coupons include the actual final support geometry on a sacrificial base; stock is listed separately.

**Treatment:** Print at the same orientation/material/process as the corresponding front-shell features and measure the channels/slot.

**Verification:** Valid one-solid STEP; manufacturing STL check accompanies final manifest.

**Remaining test:** Use actual wire and tape for insertion/5N/10cycle checks. Coupon success is necessary but does not certify whole-case drops or life.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-J9-SERVICE"></a>

## J9-SERVICE — Rear opening and PCB removal

**Components:** PHR-5, all J9 wires, P01, PCB

**Concern:** Insufficient accessible slack pulls solder joints or thin printed features apart.

**Loading:** Assembly, maintenance and disassembly.

**Evidence:** CAD defines installed routes, not a certified opening angle or stored service loop. Stock+20mm is a cutting allowance.

**Treatment:** Keep PCB and front assembly supported together. UnplugPHR5 by its body before lifting PCB. Feed the PTT upper wire before final soldering. Replace removable tape after access.

**Verification:** Written sequence and explicit slack gate; no physical opening test claimed.

**Remaining test:** Demonstrate unpowered opening/disconnection without tension, scraping or pinching. Trim stock to the verified route; do not hide the20mm allowance in an unmodelled loop. Full front-shell replacement may require contact depinning or solder service.

**Status:** CAD geometry prepared; physical and electrical release gates remain

<a id="risk-ADAPTER_FAB_01"></a>

## ADAPTER_FAB_01 — Two holes atX21/23,Z−6.7 throughY−5…−4

**Components:** fabricated FR4 carrier, B2B-PH-K-S(LF)(SN) header

**Concern:** Incorrect hole row or finished drill/plating forces or bends the header tails; loose or damaged anchorage.

**Loading:** Header population and connector mating/service.

**Evidence:** Old holes offset0.6mm produced0.6432mm³ source-pin overlap. Corrected holes yield0 overlap and0.07145mm nominal modeled pin-to-bore gap. JST reference hole is0.7+0.1/0 and notes hard-FR4 enlargement may be needed.

**Treatment:** Corrected hole row; twoØ0.95±0.03 plated holes, isolatedØ1.6 pads, finished8x6x1 outside envelope, body-grip service and separate soft-supported seat.

**Verification:** Valid1solid carrier; full current neighbor check has no unintended intersection; dimensioned drawing visually read.

**Remaining test:** Measure finished carrier and fit received header freely; verify pad/barrel solder anchorage and10 service cycles.

**Status:** CAD_PASS_PHYSICAL_GATE

<a id="risk-ADAPTER_FAB_02"></a>

## ADAPTER_FAB_02 — X21/23,Y−9.96…−5,Z−8.23…−5.8

**Components:** two CK pigtail direct-lap joints, two insulating sleeves, rear pad coatings

**Concern:** Cold lap, damaged strands, exposed pin or solder bridge; pull load reaches the joint or insulation rubs the cover.

**Loading:** Soldering, wire dressing, installation and5N service pull.

**Evidence:** Source bare tails and modeledØ0.48 cores are wholly contained in the new insulation envelope. Two insulated envelopes retain0.20mm nominal gap; K03 gap0.60374mm and split clamp gap0.34139mm.

**Treatment:** Direct wire-to-metal-tail lap, each branch independently sleeved and rear-pad covered; preserve fixed jacket endpoints and use the separate split-silicone clamp. No solder/insulation outside checked maximum envelopes.

**Verification:** Exact containment volume0 and no unintended full-neighbor intersections. Approximately1.2mm full-section lap available in source geometry.

**Remaining test:** Qualify actual core/strip length, solder wetting and insulation material/coverage, sleeve separation and5N/10cycle retention; do not power an unverified joint.

**Status:** CAD_PASS_FABRICATION_GATE

<a id="risk-ADAPTER_FAB_03"></a>

## ADAPTER_FAB_03 — A/B paths on the adapter and their board endpoints

**Components:** passive adapter two isolated connections, main-board battery input, intact factory battery plug

**Concern:** Reversed polarity, A-B short or excess resistance/current heating despite mechanical fit.

**Loading:** First connection, operation and charging.

**Evidence:** Geometric A/B labels do not establish electrical pin numbering. JST2A rating is specified withAWG24; routed26AWG assembly is not electrically qualified.

**Treatment:** No cross-net copper or traces; current travels through direct wire-to-tail lap. Preserve factory pack leads/plug, map actual polarity and board nets with documentation/continuity, grip connector bodies.

**Verification:** Two distinct carrier pads and bounded termination envelopes; electrical continuity/current tests not performed.

**Remaining test:** Verify battery polarity and board mapping, A/B continuity and isolation, actual current/contact/temperature limits and strain relief before energized assembly.

**Status:** ELECTRICAL_RELEASE_HOLD

<a id="risk-CTRL_K03_REAR_ACCESS"></a>

## CTRL_K03_REAR_ACCESS — Adapter receiver and cable-grommet cover

**Components:** K03, P01, H10, QF01B

**Concern:** Former horizontal screw heads/shafts occupied grommet webs; thin receiver ligament may split during thread formation; carrier can be pinched by an incorrect seat.

**Loading:** Tightening, cable pull, installation and repeated service.

**Evidence:** ['K03_pair_and_access.json', 'K03_local_strength.json', 'K03_REAR_ACCESS_REVIEW.md', 'K03_preassembled_insertion.json', 'K03_final_removal_delta.json']

**Treatment:** Two rear-access M2x6 pan screws,2mm hard-seated ears,6mm-deep grommet crossbar with independently supported minimum2.025/2.14mm rails, rounded positive-clearance insulation passage, controlled pilot/thread qualification; original electronics/exterior fixed.

**Verification:** Final580eec geometry valid1solid; paired full-hostzero common;9 preassembled rear insertion positions; D3rear driver with PCB removed; correctedinsulation gap.36mm; hypothetical8MPa/2xroot screens max7.28MPaweb/7.07lowerrail/6.33upperrail, deflection<.010mm. Supersedes earlier6.94MPaweb-only claim.

**Remaining test:** Print QF01B in final process; qualify actual pilot/thread method, head size, ten service cycles and cable retention. No screw torque/thread strength or cable pull rating is certified.

**Status:** Nominal geometry and bounded analytical screens pass; physical qualification open.

<a id="risk-PTT-PAD-MOTION"></a>

## PTT-PAD-MOTION — Fixed facing outboard edgeX-36.7,Y12.5..21.5,Z-12.7..-12.2

**Components:** PTT fixed rear keeper facing, P05 moving carrier, P08 switch cradle, P01 central support, R36_STOCK_PTT_REAR_PAD_TRIMMED_5p2x9x0p50_FINAL, P05, P08, P01

**Concern:** Old facing overhang enters moving carrier after0.25mm travel, adding drag or sustained preload and potentially preventing release.

**Loading:** PTT press/release through0.45mm travel and off-centre handling.

**Evidence:** Old pad overlap0.225mm³ at0.30mm travel. A0.50mm edge trim retains91.23% overall facing area and all exact fixed housing/cradle/shell contact areas. The new stock is a strict subset of the old reference.

**Treatment:** Trim only outboard edge; preserve0.50mm installed thickness, inboard datum and all rigid support contact areas. No rubbing or forced compression is credited.

**Verification:** Seven translations of carrier/grip/contact/bond, continuous distance bounds, eight midstroke rocking poses for each mover, removal-only proof and all206 local static pairs pass. Exact values in PTT_PAD_MOTION_CORRECTION_CHECKS.json.

**Remaining test:** Root final full-motion run after integration, actual cut-edge placement/installed thickness, reliable electrical release,10 service cycles and1000 PTT actuations without drag or pad creep.

**Status:** LOCAL_CAD_PASS_FULL_MOTION_RERUN_REQUIRED

<a id="risk-ACCESS-FRONT-ORDER"></a>

## ACCESS-FRONT-ORDER — Front retainer, PTT and adapter screw-driver corridors

**Components:** P01, P04, P11, P12, P13, P14, P17, P18, K03, F01, C28_R2_REF_PCB_fb5acde7_SHA30578154, R36_J8_LED_PH_LEAD_2_OD1p05_R3, R36_J8_LED_PH_LEAD_3_OD1p05_R3, R36_J8_LED_PH_LEAD_4_OD1p05_R3

**Concern:** A driver can load the installed PCB, wires or opposite shell when attempting a front screw after those items are installed.

**Loading:** Initial fastening and service with a straight hand driver.

**Evidence:** All front fastener paths clear with the rear subassembly/PCB absent; one lower speaker tool crosses the final J8 wires. K03 driver paths are blocked by the installed PCB. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)

**Treatment:** Fasten front retainers and the preassembled adapter before PCB installation, with F01/rear assembly separate. Dress J8 after the speaker screws are seated; remove board and release local dressing for service.

**Verification:** Exact Ø3 × 30 mm outward shaft against all other selected bodies, with every positive intersection individually classified by assembly stage; no unresolved staged hit.

**Remaining test:** Actual bit/drive and handle fit, tool alignment, printed tolerance, hand tightening and ten assembly/service cycles.

**Status:** NOMINAL STAGED CAD ACCESS CLEAR; PHYSICAL QUALIFICATION OPEN

<a id="risk-ACCESS-REAR-WIRE-ORDER"></a>

## ACCESS-REAR-WIRE-ORDER — Rear antenna, battery and volume keeper tool paths

**Components:** P02, P15, P16, P19, P20, K01, K02, F01, R36_FACTORY_BATTERY_LEAD_2_100mm_INWARD_RISER_FINAL, J9_COMMON_LINK_1_OD1p05_R3

**Concern:** A driver can pinch or abrade a final dressed lead, or strike the battery while attempting an upper antenna screw.

**Loading:** Rear keeper fastening and later component removal.

**Evidence:** Battery screw 3 crosses factory lead 2 by 1.1174 mm³; K01 screw 1 and K02 screw 2 cross J9 common link 1 by 2.5612/0.7011 mm³. Upper antenna tools cross the maximum pack. All clear with the named staged items absent. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)

**Treatment:** Work with front assembly/PCB and F01 separate; fit antenna before battery. Fasten K01/K02 before J9 common-link dressing and battery keepers before intact factory lead2 dressing. Release local dressing for service; never use the tool to displace a lead.

**Verification:** All rear fastener Ø3 × 30 mm shaft paths classified individually. No local rigid host/keeper obstruction; no factory cable or solder endpoint changes.

**Remaining test:** Demonstrate the intact leads can remain free and be dressed without tension, pinch, abrasion or unqualified bends. Confirm actual tool/tolerances and ten service cycles.

**Status:** NOMINAL STAGED CAD ACCESS CLEAR; FLEXIBLE HANDLING UNTESTED

<a id="risk-ACCESS-CLOSURE-BUMPER"></a>

## ACCESS-CLOSURE-BUMPER — Four rear case-closure screw tool paths under F01

**Components:** F01, P01, P02, C27_R2_HW_Closure_-33_4_-56, C27_R2_HW_Closure_33_4_-56, C27_R2_HW_Closure_-33_4_56, C27_R2_HW_Closure_33_4_56

**Concern:** Attempting closure or service through the fitted bumper would damage the bumper or prevent straight bit engagement.

**Loading:** Case closure and opening.

**Evidence:** Each outward Ø3 × 30 mm closure tool intersects fitted F01 by 6.4340 mm³; every other selected object clears. audit/fixtures/driver_access_final/FINAL_DRIVER_ACCESS_REPORT.json (manifest 77d9a0a5675bf7fb0d123d983df8f920fc91d25a51c6047403f8f0ce551e793d)

**Treatment:** Hand-seat the populated halves and tighten all four closure screws with F01 off. Fit the removable flexible bumper afterward; remove it first for service.

**Verification:** Exact shaft test retains both shells and all installed internals; F01 is the sole exclusion for closure.

**Remaining test:** Qualify bumper installation/removal without damage, actual bit/handle fit and ten closure/service cycles.

**Status:** NOMINAL STAGED CAD ACCESS CLEAR; PHYSICAL QUALIFICATION OPEN