# Feature-level risk register

156 concerns. Original evidence is retained separately from each current treatment. No physical test is marked passed.

| ID / location | Failure / loading | Current treatment | Status |
|---|---|---|---|
| R36-PA-01 — Four closure joints at X +/-33.4, Y +/-56 | Short receiving threads strip or pull out; a long screw can still engage only a short thin receiver. Initial thread formation, tightening, ten service cycles and case pull-apart load. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-02 — Upper receiver inboard faces beside maximum battery | Enlarged bosses can consume pouch clearance; aggressive relief can leave a fragile unsupported wall. Battery installation, closed-case shock and tightening. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-03 — Rear closure countersinks and surrounding shell | Countersink wedge loads split the seat or dish the rear skin. Tightening and case closure. | Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-04 — Exterior and mating seam | A local reinforcement changes outside shape, creates an interference, or causes closure distortion. Printing, fitting bumper and final closure. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Original contour/openings fixed. Flexible material remains a distinct manufacturing requirement; fit after closure screws. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-05 — Speaker screw ears and transverse beams | Narrow countersink ligaments split; thin beam bends into the speaker or loses retention. Loose handling, screw seating, vibration and servicing. | One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-06 — Speaker blind screw pilots | Screw bottoms before clamp seats or breaks the front skin. Assembly tightening. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-07 — Microphone keeper screw seats | Countersink wedging or blind-hole bottoming; reinforcement may collide with PTT. Screw tightening, control movement and servicing. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-08 — Mic board, bottom acoustic port and offset seal | Fastening bends board, crushes components or blocks acoustic path. Seating, pad compression and acoustic operation. | Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-09 — LED keeper screw ears and blind pilots | Countersink splitting, keeper bending or screw bottoming. Insertion, tightening and removal. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. One flat plate holds the original LED upright beside the PCB. One M2x4 screw, open four-lead exit, hard-supported seat. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-10 — LED package, coupler and four lead exits | Keeper preload chips optics or cracks lamp; wire pull bends soldered leads. Lamp installation, cable connection and servicing. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-PA-11 — Lens rear flange pocket and fixed visible throat | A brittle interference fit chips lens or splits the seat. Insertion/removal and an external finger press. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original exterior lens and throat retained. Existing optical part can be reused if undamaged; printed opaque proxy is only a fit gauge. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-12 — Lens flange and visible cap | Thin radial shoulder chips during loose handling or overloading. Handling before capture and pressing after assembly. | Original exterior lens and throat retained. Existing optical part can be reused if undamaged; printed opaque proxy is only a fit gauge. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-13 — Right-angle coupler and thin coupling film | Small optic chips under uneven compression; adhesive squeeze-out blocks light. Assembly, keeper seating and thermal cycling. | New4x3mm clear periscope to the relocated original LED, with two broad adhesive tabs and45deg turning faces. Optical output must be tested; opaque printing is a fit proxy only. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-14 — Grille locating lip and mesh/scrim perimeter | 1.2 mm lip chips while loose; force fitting distorts grille; bond peels during removal. Support removal, mesh installation, handling and servicing. | Original grille geometry, mesh and acoustic stack fixed. Handle on a flat tray; avoid force fits. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-15 — Flexible rim, corner turns and opening bridges | Tearing at thin bridges, excessive stretch or brittle rigid-material substitution. Installation/removal and corner impact. | Original contour/openings fixed. Flexible material remains a distinct manufacturing requirement; fit after closure screws. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-16 — Talk grip and its 0.10 mm bond stack | Edge peel, tearing or excess bond thickness blocks return. Side presses, repeated control use and removal. | Original visible shape and0.10mm bond stack fixed. Separate flexible material; test peel and end presses. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-17 — All pads, films, seals and component contact surfaces | Doubled layers or free-stock thickness adds preload; foam creep unloads capture or bows electronics. Initial assembly, closure, temperature exposure and servicing. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-18 — Support removal, loose handling, driver access and teardown | A sound assembled component breaks before installation or during removal. Postprocessing and every service step. | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-19 — Process qualification coupons and grille handling tray | Coupon does not reproduce weak direction or support removal, producing a misleading pass. Coupon printing, postprocessing and destructive tests. | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-20 — Long microphone-frame rails and corner transitions | Thin ring bends or breaks before installation; unsupported point loading can damage a retained but unbroken part. Loose-part handling, seating and pad reaction. | Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PA-21 — Speaker upper central tab, X +/-6, Y67.61..68.90 | Original rigid speaker tab intersects the inner curved case by4.234mm3, forcing assembly or lifting its seat. Speaker insertion, keeper tightening and closure. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-PCB-01 — Four original front/rear support pairs | Small supports flex, split at roots or transmit concentrated pad load into board. Loose handling, closure, connector insertion/pull and service. | Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained. | REDESIGNED; current geometry audit and physical support-force test required |
| R36-PCB-02 — Lower-right PCB edge nearJ1 | Large unsupported board overhang permits board bending and connector stress. Connector insertion, closure and service. | Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained. | REDESIGNED; current geometry audit and physical support-force test required |
| R36-PCB-03 — Mid-right front backing under side-header area | PCB bends when a side connector is inserted or operated. Mating and cable insertion. | Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained. | REDESIGNED; current geometry audit and physical support-force test required |
| R36-PCB-04 — Long surrounding board edge/location rails | Thin edge rail or cut wire window cracks; lateral board movement loads fixedUSB/header interfaces. PCB insertion/removal, wire routing and connector pull. | Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained. | REDESIGNED; current geometry audit and physical support-force test required |
| R36-PCB-05 — Eleven installed PCB pad locations after revision | Doubled stock, adhesive thickness or excessive compression bows the board. Case closure and thermal/service cycling. | Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained. | REDESIGNED; current geometry audit and physical support-force test required |
| R36-BAT01 — Main bay and upper corners | Zero-clearance forced insertion splits tall rails; oversize pouch clashes with originalcorner skin Top insertion/removal and package dimensional variation | Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-BAT02 — Upper bay and four head pockets | Internalclearancecuts maythin rigid exterior skin Handling/case closure/point impact | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-BAT19 — Plate, neck, ears, locating toe and outward-open wire port | Neck bending, hole-edge splitting, pouch pointload, or wire pinching 5Nservice perkeeper; conservativeone-ear concentration included | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-BAT20 — Plate, neck, ears, locating toe and outward-open wire port | Neck bending, hole-edge splitting, pouch pointload, or wire pinching 5Nservice perkeeper; conservativeone-ear concentration included | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-BAT03 — AnchorsX±33.4;leftY44.4/50.9,right37.5/50.9 | Pilot interference or excess tightening splits post; insufficient thread engagement strips receiver Keeper installation/removal | Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-BAT04 — Rear support, front keeper faces and lower toe faces | Over-thick stock preloads pouch; absentstock allows rattling/rubbing Pack retention andservice travel | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-BAT05 — Samefourcontactlocations | Usingthick nominalpackpads withmaximum pack squeezes pouch Assembly variantselection | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-BAT06 — Lowerpouch edge atY27.18min versusPCBedgeY26.96 | Pouch abrasion onPCBedge due movement/tolerance/rocking Removal,packtilt andretention | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-BAT07 — Righttab after180°inplanerotation; risersY47.65 | Wirepinch, damagedprotectedtab, insufficientleadlength orincorrectadapterpolarity Caseclosure andservice | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-BAT08 — Inertmaxgauge, XYfitcoupon androot/keepertestcoupons | Uncalibrated print givesfalsefit; couponpassing mistakenforfullpartqualification Shopcalibration andfirstarticle | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-BAT_FINAL_CONTACT — P19 lower ear near(-33.4,44.4); P20 outboard lower locating toe | Interference in final assembly transfers closure/retention force into a keeper or switch terminal. Shell closure and battery service. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Broad removable plate retained. One broad keyed left mount atY46.2 clears the PTT guide and speaker rise; the obsolete window is filled. Pouch remains uncompressed. Broad plate and original right anchors retained. Open factory-lead and volume-return clearance; no thin snap features. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P03 — Play cap, bar ends and root connections | Cap flexure, broken capture bars or pocket binding Loose handling, edge pressing, insertion and hard stop | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Fixed visible form and broad R3.6 capture bars retained. Separate moving member remains necessary; screen0.50mm travel and physical release. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P04 — Clamp beam, raised ring, mounting ears and solder access | Beam flexure, screw-seat splitting, terminal pinch Switch load, tightening and service | Clear tilted PCB and insulated play terminals; one paired PCB support now grows from this stationary clamp. Retain two original screw axes and supported bearing surfaces. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P05 — PTT skin, internal backing, slider roots and heads | Broken long rods/webs, skin bending and switch overtravel Uncaptured handling, end/centre press and hard press | Retain the short captured R3.6 mechanism, broad roots, original visible shape and end stops. Physical end presses remain required. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P06 — Original visible cap and new stem/flange roots | Root/head break, cap bending and slider rocking Handling, edge press, outward pull and overtravel | Broad captured slider replaces the original fragile legs. Independent motion retained; do not glue to the combined rail. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P07 — Original visible cap and new stem/flange roots | Root/head break, cap bending and slider rocking Handling, edge press, outward pull and overtravel | Same broad slider principle, independent return and fixed visible shape; new button harness passes through an open neighbouring channel. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P08 — Cradle roof and side rails | Roof/rail damage, switch mis-seat or terminal strain Loose handling, assembly and switch force | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Now part of P01, with a broad supported inner bearing around the insulated terminal exits. No loose cradle to handle or force into place. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P09 — Cradle roof and side rails | Roof/rail damage, switch mis-seat or terminal strain Loose handling, assembly and switch force | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Now part of P01; open rear access accepts a prewired switch without snapping rails. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P10 — Cradle roof and side rails | Roof/rail damage, switch mis-seat or terminal strain Loose handling, assembly and switch force | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Now part of P01; keep the wired terminal pair inside the modeled insulation envelope. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P17 — PTT keeper roof, recessed ears and end stop | Guide break, pinching, coupled binding or ear splitting Screw tightening, edge pressing, outward capture | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Short supported guide and two accessible screws. Keeping it separate preserves the LED/wiring corridor. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_P18 — PTT keeper roof, recessed ears and end stop | Guide break, pinching, coupled binding or ear splitting Screw tightening, edge pressing, outward capture | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Second short guide maintains local support and PTT end-press control; no unsupported joining bridge. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_K01 — Volume keeper roof, stop lands, screw ears and supporting floor | Roof bending, stop fracture or seat damage Edge press, hard press and screw tightening | Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Both stationary retainers become one shell-supported rail. Four original screws and independent travel stops retained; the joining span has a continuous rear bed. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_K02 — Volume keeper roof, stop lands, screw ears and supporting floor | Roof bending, stop fracture or seat damage Edge press, hard press and screw tightening | Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Now part of K01. No second loose rail. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_RECEIVERS — Guide bases, joint roots and preserved outer skin | Receiver fracture, residual wall damage or exterior changes Press loads, screw preload, case opening | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_PTT_CENTRE — Central bridge, flanking pillars and pad seat | Centre skin flexure adds travel beyond end stops Hard press after nominal stroke | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_K01_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_K01_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_K02_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_K02_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_P17_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_P17_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_P18_M2x6_PAN_1_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_HC_P18_M2x6_PAN_2_REFERENCE — Keeper screw, pilot and driver approach | Pilot stripping, split boss or head collision Tightening and10 service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_QC01_VOLUME_RECEIVER_PROCESS_COUPON — Process coupon contacts | False confidence from different process or incomplete scope Print qualification | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_QC02_PTT_RECEIVER_PROCESS_COUPON — Process coupon contacts | False confidence from different process or incomplete scope Print qualification | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_QC03_SCREW_PILOT_COUPON — Process coupon contacts | False confidence from different process or incomplete scope Print qualification | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-CTRL_PADS_RETURN — Actual switches, rest gap, pad compression and return | No click, preload, sticking, coupled controls or overtravel Normal presses, hard stops and tolerance stack | Fixed visible form and broad R3.6 capture bars retained. Separate moving member remains necessary; screen0.50mm travel and physical release. Clear tilted PCB and insulated play terminals; one paired PCB support now grows from this stationary clamp. Retain two original screw axes and supported bearing surfaces. Retain the short captured R3.6 mechanism, broad roots, original visible shape and end stops. Physical end presses remain required. Broad captured slider replaces the original fragile legs. Independent motion retained; do not glue to the combined rail. Same broad slider principle, independent return and fixed visible shape; new button harness passes through an open neighbouring channel. Now part of P01, with a broad supported inner bearing around the insulated terminal exits. No loose cradle to handle or force into place. Now part of P01; open rear access accepts a prewired switch without snapping rails. Now part of P01; keep the wired terminal pair inside the modeled insulation envelope. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-P15 — Lower antenna frame, X±17,Y−36.5..−27.5 | Original narrow bridge and thin seats can bend or split; bottoming/preload can overload the antenna flex. Screw tightening, handling and5N service load | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-P16 — Upper antenna frame,Y57..67 | Thin cable bridge/ear bending or antenna preload can crack a printed frame. Handling, clamp preload, cable snag | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-REAR-BED — X±11.25,Y−35.5..62.5,Z−22.10; four nylon pilots | Broad skin recess lowers stiffness; pilot floor or edge may split if screws bottom. External handling, screw installation, closure pressure | Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-ANT-RF — Rear central antenna footprint | Detuning and efficiency loss despite mechanically clear surfaces. Powered radio operation | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-K03 — X~14.4..29.6,Y−12.3..0,Z−10.55..−2 | Mating forces, solder-joint fatigue, printed root/cover fracture or wire pullout. Factory plug mating/unmating and pigtail service pull | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-HA-1 — Adapter transverse fastener axes | Printed threads strip, root splits or screw bottoms before clamping. Hand assembly and repeated service | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-HA-2 — Adapter transverse fastener axes | Printed threads strip, root splits or screw bottoms before clamping. Hand assembly and repeated service | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-CK-J2 — Fixed original J2 header | Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current. Mating, cable routing and electrical operation | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-CK-J3 — Fixed original J3 header | Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current. Mating, cable routing and electrical operation | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-CK-J10 — Fixed original J10 header | Wrong socket variant/wire-center datum, insulation displacement failure, extraction load or excessive current. Mating, cable routing and electrical operation | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-PH-J8 — Original side-entry J8 | Plug housing or wire exit can hit wall; crimp pull can load header solder. Mating and service cable pull | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-LED-JOINTS — Four distal LED leads at1.27mm pitch | Oversized solder/insulation sleeves crowd neighboring legs and cause bending or shorts. Harness dressing and service vibration | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-SPK-LEADS — Left front harness and X−23.6/Y5..13, X−26.8/Y−5..3 | Speaker lead exit uncertainty, bulky splice or unsupported pull can break a lead or pinch it against a support. Speaker assembly and service removal | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-BAT-LEADS — Right keeper service opening and front speaker annulus | Lead forced around screw head, sharp edge, insufficient length or pouch-tab pull. Battery insertion, closure and service | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-MIC-WINDOW — Left wall nearY−28..−22 | Several close round bores leave thin fins or sever a PCB/guide support. Wire insertion and shell handling | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-MIC-SADDLE — X−21.5..−15.5,Y−33..−17 | Adhesive peel, wire slip or saddle break lets pull reach microphone/PCB joints. 5N service pull and repeated assembly | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-COAX — New right-side rear route | Cable bend/abrasion or unretained loop pulls RF connector or antenna feed. Assembly and service handling | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-J8-SADDLE — X15.5..18.8,Y−42.5..−26.2 | Adhesive peel or bundle slip passes load to the PH header or LED legs; a crossing control wire can be pinched. Cable insertion,5N service pull and closure | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-STOCK-R36_STOCK_ANTENNA_CARRIER_ADHESIVE_0p05 — [[-10.2, -34.2, -22.1], [10.2, 61.2, -22.05]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_1_INSTALLED_0p42 — [[-9.5, -33.75, -21.75], [-4.5, -29.75, -21.33]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_2_INSTALLED_0p42 — [[4.5, -33.75, -21.75], [9.5, -29.75, -21.33]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_3_INSTALLED_0p42 — [[-9.5, 57.25, -21.75], [-4.5, 61.25, -21.33]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ANTENNA_END_PAD_4_INSTALLED_0p42 — [[4.5, 57.25, -21.75], [9.5, 61.25, -21.33]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ANTENNA_PET_DIELECTRIC_0p10 — [[-10.2, -34.2, -22.05], [10.2, 61.2, -21.95]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_FRONT_INSTALLED_0p25 — [[18.0, -4.0, -10.3], [18.8, -3.75, -4.3]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_1_REAR_INSTALLED_0p25 — [[18.0, -5.25, -10.3], [18.8, -5.0, -4.3]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_FRONT_INSTALLED_0p25 — [[25.2, -4.0, -10.3], [26.0, -3.75, -4.3]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ADAPTER_CARRIER_EDGE_PAD_2_REAR_INSTALLED_0p25 — [[25.2, -5.25, -10.3], [26.0, -5.0, -4.3]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_ADAPTER_SPLIT_SILICONE_GROMMET_INSTALLED — [[19.1, -12.3, -8.600000001016], [24.9, -10.3, -5.999999998983999]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_1_L4 — [[30.149999899999997, -26.0000001, -22.085000100000002], [32.833986543971, -21.9999999, -19.649999899999997]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-STOCK-R36_STOCK_COAX_FORMED_SILICONE_TACK_2_L4 — [[30.15, -9.0, -22.085], [32.83398644397425, -5.0, -19.65]] | Incorrect installed thickness, creep, compression set or delamination changes preload and wire grip. Assembly preload, temperature and service cycles | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-J8-CORNER — X15.4…18.9,Y−42.6…−40.6,Z−10.5…−7.79 | J9 clearance sweep leaves0.65mm lip that can fracture or trap a control wire. Assembly, cable pull, control service | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-J8-STRAP — J8 saddle rear face and newY−40.6 end face | Insufficient bonded land or wire abrasion permits slip and loads solder joints. 5Nservice pull and repeated assembly | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-FINAL-COAX-STRAP-1 — Right rear cable runY−37…−33 | Chemical bond to FEP is unreliable; flat tape contours enter curved wall; axial cable slip loads RF feed/plug. Cable dressing and5Nservice screen | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-COAX-PAD-1 — Under coax within existing clearance channel | Pad too hard/thick crushes coax; too soft/thin loses preload and friction. Strap installation, dwell, service pull | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-COAX-STRAP-2 — Right rear cable runY−22…−18 | Chemical bond to FEP is unreliable; flat tape contours enter curved wall; axial cable slip loads RF feed/plug. Cable dressing and5Nservice screen | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-COAX-PAD-2 — Under coax within existing clearance channel | Pad too hard/thick crushes coax; too soft/thin loses preload and friction. Strap installation, dwell, service pull | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-SPEAKER-LEAD2 — Left front route withX−27.4,Y22…10,Z−8.9 | Factory lead crosses fixedPTTsignal/common wires or rubs new channel. Speaker insertion/service | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-SPEAKER-SLEEVE1 — X−23.6,Y5…13,Z−4.4 | ClosePTTsignal adjacency or insufficient insulation creates rubbing/short risk. Harness dressing andvibration | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-FINAL-KEEPER-PORTS — Openwireports andupperanchor neckedges | Clearance cuts might sever a narrow neck or screw-seat roof. 5Nkeeper service andscrewpreload | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-COUPON-QF04B_J8_REAR_OPEN_CORNER_AND_FORMED_STRAP_TEST_BASE — Testcoupon | Unrepresentativeprocess orsurfacefinish makes test misleading. Firstarticle qualification | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-FX-COUPON-QF05_COAX_CURVED_LANDS_AND_CABLE_SADDLE_TEST_BASE — Testcoupon | Unrepresentativeprocess orsurfacefinish makes test misleading. Firstarticle qualification | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-FINAL-BATTERY-INWARD-RISERS — Right battery lead rise and keeper port, Y about39…46mm | Outer wire-clearance sweep breached the fixed curved front exterior; inward reroute can pinch a wire against a head or weaken its keeper port. Battery insertion, hand closure and service cable dressing | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-FX-ADAPTER-FINAL-BASE — Adapter seat and two rear-access receiver posts | 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. Carrier insertion, connector mating, tapping, cable pull and service | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-ADAPTER-FINAL-COVER — Rear-access cover, grommet webs and 2 mm screw ears | A screw head inside an old grommet web prevents assembly; cutting away head support can leave a fragile cover. Tightening, wire grip, connector pull and installation | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-ADAPTER-FINAL-SCREW-1 — Adapter screw axis X15.6, Y−6.05 | Pilot cracking, thread strip, bottoming or crushed carrier pads from uncontrolled tightening. Assembly tightening and repeated removal | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-ADAPTER-FINAL-SCREW-2 — Adapter screw axis X28.1, Y−6.05 | Pilot cracking, thread strip, bottoming or crushed carrier pads from uncontrolled tightening. Assembly tightening and repeated removal | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-ADAPTER-FINAL-PAD-LANDS — Four carrier edge pads and front backing columns | Thin unsupported ledges bend; excessive pad compression or misassembly loads the carrier/header pins. Mating/pull load and cover tightening | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-ADAPTER-FINAL-GROMMET — Outgoing insulated CK pair at K03 | Cable pull reaching solder joints, insulation abrasion or silicone slip. Cable dressing and 5 N service pull | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-ADAPTER-FINAL-CK2 — Manufactured CK2 front lane | A channel too close to the pilot leaves a thin torque-loaded wall; poor wire dressing can rub or pull contacts. Assembly and service motion | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-ADAPTER-FINAL-COUPON — Qualification coupon | A generic post coupon can miss the final thin ligaments, pad/backer geometry and wire channels. Print qualification before first assembled article | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-FX-MIC-FACING-FINAL — Microphone facing at X−21.5…−15.5, Y−30…−19.5, Z−8.975…−8.725 | The original facing overlapped the rising formed strap by 0.147692 mm³, risking a folded edge, uncontrolled preload or strap lift. Tape application, cable dressing and microphone bundle pull | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-ROUTES — Original side-entryJ9 to the four unchanged switch locations | Wire pinch, scraping, sharp bends or cable forces transmitted to connector/solder joints. Assembly, control presses and opening/service. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-SHELLS — Local cable channels and terminal pockets | Internal relief removes load-bearing stock or changes the locked exterior. Shell closure and fastener loads. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-TERMINALS — Nominal switch legs | Bare solder, wrong contact pairing, oversized sleeves, or bending a terminal against a printed cradle. Soldering, wire dressing and control operation. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-COMMON-JUNCTION — X17…23,Y23.4,Z−11.25 | A bulky or exposed branch joint collides with PCB, battery toe or control guide. Harness assembly and service pull. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-PTT-SUPPORT — X−25.5…−20.5,Y−15.5…−12.5 | Support splitting or an unremovable wire forced through a printed passage. Wire insertion and service loads. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-PTT-TAPE — 5×3×0.10mm installed rear strip | Adhesive peels and the return leaves its groove. Service handling and cable movement. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-JUNCTION-SUPPORT — Shelf X17…29.5,Y18.5…24.8; root X25…29.5,Y14.5…18.5 | Unsupported splice bends solder joints or support interferes with nearby wiring. Wire dressing and service pull. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-JUNCTION-LOOP — 2.5mm wide loop through the support slot | Loop loosens or adhesive fails, loading the three-way joint. Service pull and vibration. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-COUPONS — Standalone exact-support print coupons | A failed print process is used directly in the complete shell. Pilot printing and assembly qualification. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-J9-SERVICE — Rear opening and PCB removal | Insufficient accessible slack pulls solder joints or thin printed features apart. Assembly, maintenance and disassembly. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-ADAPTER_FAB_01 — Two holes atX21/23,Z−6.7 throughY−5…−4 | Incorrect hole row or finished drill/plating forces or bends the header tails; loose or damaged anchorage. Header population and connector mating/service. | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-ADAPTER_FAB_02 — X21/23,Y−9.96…−5,Z−8.23…−5.8 | Cold lap, damaged strands, exposed pin or solder bridge; pull load reaches the joint or insulation rubs the cover. Soldering, wire dressing, installation and5N service pull. | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-ADAPTER_FAB_03 — A/B paths on the adapter and their board endpoints | Reversed polarity, A-B short or excess resistance/current heating despite mechanical fit. First connection, operation and charging. | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-CTRL_K03_REAR_ACCESS — Adapter receiver and cable-grommet cover | Former horizontal screw heads/shafts occupied grommet webs; thin receiver ligament may split during thread formation; carrier can be pinched by an incorrect seat. Tightening, cable pull, installation and repeated service. | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-PTT-PAD-MOTION — Fixed facing outboard edgeX-36.7,Y12.5..21.5,Z-12.7..-12.2 | Old facing overhang enters moving carrier after0.25mm travel, adding drag or sustained preload and potentially preventing release. PTT press/release through0.45mm travel and off-centre handling. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Retain the short captured R3.6 mechanism, broad roots, original visible shape and end stops. Physical end presses remain required. Now part of P01, with a broad supported inner bearing around the insulated terminal exits. No loose cradle to handle or force into place. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R36-ACCESS-FRONT-ORDER — Front retainer, PTT and adapter screw-driver corridors | A driver can load the installed PCB, wires or opposite shell when attempting a front screw after those items are installed. Initial fastening and service with a straight hand driver. | Superseded mechanism removed from the current assembly. Direct J2/J10 PH connections, adhesive antenna mounting and current routing replace it; see current reference assembly. | REMOVED_OR_REPLACED_MECHANISM; physical replacement qualification pending |
| R36-ACCESS-REAR-WIRE-ORDER — Rear antenna, battery and volume keeper tool paths | A driver can pinch or abrade a final dressed lead, or strike the battery while attempting an upper antenna screw. Rear keeper fastening and later component removal. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| R36-ACCESS-CLOSURE-BUMPER — Four rear case-closure screw tool paths under F01 | Attempting closure or service through the fitted bumper would damage the bumper or prevent straight bit engagement. Case closure and opening. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. Original contour/openings fixed. Flexible material remains a distinct manufacturing requirement; fit after closure screws. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-01 — Upright connector tails | Case cannot seat; plug/wire or PCB is loaded by closure. Inserting complete PCB and closing case. | Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-02 — Laminate and solder-pin datums | Incorrect supports squeeze/bow board or collision occurs at solder tips. Installation, closure, USB insertion. | Four paired supports and four defined pads replace eleven pads; complete PCB moved with all component envelopes including U6. Wider supported right edge stop takes USB load.1.8mm laminate bound and original front datum retained. | REDESIGNED; current geometry audit and physical support-force test required |
| FIT-03 — USB shoulder and insertion corridor | A PCB move clears rear plugs but prevents the actual USB cable seating. USB insertion/removal and connector side loads. | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-04 — Electrical pin order versus old CAD labels | Harness terminated to wrong PCB nets. Harness fabrication and first power-up. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| FIT-05 — Front obstructions during PCB relocation | Fixing rear connector space creates clamp/head/LED interference. Assembly and closure. | Clear tilted PCB and insulated play terminals; one paired PCB support now grows from this stationary clamp. Retain two original screw axes and supported bearing surfaces. One flat plate holds the original LED upright beside the PCB. One M2x4 screw, open four-lead exit, hard-supported seat. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-06 — SPH0645 solder row, ribbon and SEL jumper | Wiring is trapped by microphone keeper or relocated PCB. Mic insertion and closure. | Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-07 — Speaker terminal exits and two splices | Splices occupy unmodeled volume or transmit pull to delicate leads. Speaker insertion/service and case closure. | One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-08 — Protected pouch exit and lead slack | Lead is pinched/pulled or pack compressed. Battery installation, board connection and service. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| FIT-09 — RF plug and full coax route | RF plug side-load, sharp coax bend, pinching or antenna loading. Antenna installation and service. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| FIT-10 — Switch terminals and stops | Wrong same-contact pair or stop geometry preloads/damages switch. Harness build; centre/edge and simultaneous button operation. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| FIT-11 — Deleted closed wiring fixtures | New draft lacks final strain relief after eliminating difficult threading. Installation/service/lead pull. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| FIT-12 — Practical slack, tolerance and tools | Nominal ideal cable path fits but ordinary assembly cannot reproduce it. Case assembly/disassembly and screw tightening. | Functional stock/hardware retained only as named in assembly_index.json; obsolete stock retired there. Use installed thicknesses and current assembly sequence. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-13 — Temporary supports versus permanent features | Support cleanup removes structural material or leaves interference. De-supporting and loose-part handling. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. Original outer faces/seam retained. Obsolete adapter/PCB stock removed; paired PCB pads and battery supports preserved around the connected cable routes. Battery slack belongs in the centre bay. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-14 — Part consolidation spans | A lower part count produces longer flexible or fragile bridges. Button edge loads, speaker fitting and screw tightening. | One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. Second short removable keeper uses a recessed M2x4 pan screw with1.2mm bearing floor and0.35mm maximum-pouch head clearance; it permits straight speaker fitting/removal. A long bridge or permanent lip would obstruct service. Speaker frame rotates45deg about the unchanged acoustic centre. Short supported guide and two accessible screws. Keeping it separate preserves the LED/wiring corridor. Second short guide maintains local support and PTT end-press control; no unsupported joining bridge. Both stationary retainers become one shell-supported rail. Four original screws and independent travel stops retained; the joining span has a continuous rear bed. Now part of K01. No second loose rail. | REVIEWED; current nominal checks and physical qualification remain distinct |
| FIT-15 — Five-wire button harness exit | A reasonable wire turn or normal dressing space collides with the lower volume capture and shell. Board mating, wire placement, button actuation and closure. | Superseded routes/restraints are retired. Current named J2/J3/J10/J9/J8/J5/J7 envelopes, open channels and harness instructions govern; electrical mapping corrected. Factory battery and RF cables remain intact. | REPLACED_BY_CONNECTED_ROUTING; current audit plus physical dressing/strain-relief test required |
| FIT-16 — Existing internal USB tunnel obstruction | Plug shoulder contacts internal shell stock despite a nominally large external opening. USB insertion/removal. | Original outer faces retained. Integrated three switch seats, broader PTT bearing and PCB stop, repositioned PCB supports, open cable channels, revised LED and speaker seats. | REVIEWED; current nominal checks and physical qualification remain distinct |
| R37-STR-01 — USB right edge stop | Insertion force bends/slits a tall narrow stop. USB insertion/removal. | Broaden root within exterior; screen tapered section with stated load assumptions; physical cable-force test. | CAD_TREATMENT; inspect current verification results; physical qualification pending |
| R37-STR-02 — PTT inner seat and wired terminals | Wire pockets isolate the inner cradle rail. Assembly, normal PTT press and service. | Replace with broad2.95x4.8mm bearing and direct5.1mm-wide front root; carry return across its front; verify one connected solid and motion. | CAD_TREATMENT; inspect current verification results; physical qualification pending |
| R37-STR-03 — Right battery support and slack space | An oversized slack reservation undercuts the support roof. Battery handling and case closure. | Move slack between supports; lower the rear lead crossings to preserve support thickness. No disconnected battery platform may remain. | CAD_TREATMENT; inspect current verification results; physical qualification pending |
| R37-ELEC-01 — Different PCB and LED pin numbering | Green/common-cathode misconnection. Harness termination and power-up. | Explicit mapping1->1,2->4,3->3,4->2 and continuity before power. | CAD_TREATMENT; inspect current verification results; physical qualification pending |
| R37-OPT-01 — Longer two-turn optical path | Insufficient RGB indicator brightness or adhesive loss. Normal operation and service. | Use clear optical material and finished45deg faces; test all colors and inspect bonds. | CAD_TREATMENT; inspect current verification results; physical qualification pending |
| R37-CAD-01 — Wider dressing envelopes at tight bends | Self-intersecting swept clearance tool can corrupt solid subtraction. CAD generation, not a physical failure mode. | Use unioned edge envelopes/chord capsules at tight turns, verify each final solid, material loss, exterior coincidence and native mesh topology. | CAD_TREATMENT; inspect current verification results; physical qualification pending |
| R37-ASM-01 — Received hardware vs design envelopes | Ordinary actual wire dressing exceeds the modeled bound. Fully connected assembly and service. | Use the defined cable construction, dressing spaces and hand-seat first-article gate; do not enlarge the case or force closure. | CAD_TREATMENT; inspect current verification results; physical qualification pending |