# Component disposition and fragility review

21 printed component identities; 22 fasteners. Original25 and the three added28.4 identities are all accounted for. Physical durability is unqualified.

| ID | Component | Decision | Treatment / reason |
|---|---|---|---|
| P01 | Front shell | REDESIGN | 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. |
| P02 | Rear shell | REDESIGN | 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. |
| P03 | Play cap | RETAIN | Fixed visible form and broad R3.6 capture bars retained. Separate moving member remains necessary; screen0.50mm travel and physical release. |
| P04 | Play clamp | REDESIGN | 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. |
| P05 | PTT carrier | RETAIN | Retain the short captured R3.6 mechanism, broad roots, original visible shape and end stops. Physical end presses remain required. |
| P06 | Volume up slider | RETAIN | Broad captured slider replaces the original fragile legs. Independent motion retained; do not glue to the combined rail. |
| P07 | Volume down slider | RETAIN | Same broad slider principle, independent return and fixed visible shape; new button harness passes through an open neighbouring channel. |
| P08 | PTT switch cradle | INTEGRATE | Now part of P01, with a broad supported inner bearing around the insulated terminal exits. No loose cradle to handle or force into place. |
| P09 | Volume up cradle | INTEGRATE | Now part of P01; open rear access accepts a prewired switch without snapping rails. |
| P10 | Volume down cradle | INTEGRATE | Now part of P01; keep the wired terminal pair inside the modeled insulation envelope. |
| P11 | Lower speaker keeper | REDESIGN | One short radial keeper with one M2x5 pan screw.6.8x2.2mm section, hard seating boss, supported silicone contact on the frame. |
| P12 | Upper speaker keeper | REDESIGN | 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. |
| P13 | Microphone keeper | REDESIGN | Broad open exit for the low-profile solder row and SEL jumper. Two M2x4 pan screws preserve1.4mm bearing material; acoustic datum remains fixed. |
| P14 | LED keeper | REDESIGN | One flat plate holds the original LED upright beside the PCB. One M2x4 screw, open four-lead exit, hard-supported seat. |
| P15 | Lower antenna clamp | REMOVE | Use the selected antenna’s factory peel-and-stick mounting on its insulating carrier. Eliminate a loose frame, two nylon screws and end pads. |
| P16 | Upper antenna clamp | REMOVE | Same factory adhesive retention; inspect adhesion and coax load during every service test. |
| P17 | Lower PTT guide | RETAIN | Short supported guide and two accessible screws. Keeping it separate preserves the LED/wiring corridor. |
| P18 | Upper PTT guide | RETAIN | Second short guide maintains local support and PTT end-press control; no unsupported joining bridge. |
| P19 | Left battery keeper | REDESIGN | 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. |
| P20 | Right battery keeper | RELIEVE | Broad plate and original right anchors retained. Open factory-lead and volume-return clearance; no thin snap features. |
| K01 | Combined volume capture rail | COMBINE | Both stationary retainers become one shell-supported rail. Four original screws and independent travel stops retained; the joining span has a continuous rear bed. |
| K02 | Separate lower volume capture | INTEGRATE | Now part of K01. No second loose rail. |
| K03 | Battery adapter cover | REMOVE | No adapter board, cover, grommet, associated four pads or two screws. Battery plugs directly into J2. |
| F01 | Flexible bumper | RETAIN | Original contour/openings fixed. Flexible material remains a distinct manufacturing requirement; fit after closure screws. |
| F02 | Flexible PTT grip | RETAIN | Original visible shape and0.10mm bond stack fixed. Separate flexible material; test peel and end presses. |
| M04 | Grille bezel | RETAIN | Original grille geometry, mesh and acoustic stack fixed. Handle on a flat tray; avoid force fits. |
| L01 | Exterior lens | RETAIN | Original exterior lens and throat retained. Existing optical part can be reused if undamaged; printed opaque proxy is only a fit gauge. |
| L02 | Internal light guide | REDESIGN | 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. |

## Other assembly groups

| Group | Current treatment and remaining qualification |
|---|---|
| Main PCB and U6 | Reposition the complete board using the saved CAD placement; USB opening is fixed. Four paired supports act on bare laminate. The source laminate is1.33mm; the design reserves up to1.8mm with the front datum fixed. U6 uses a24x24x2.4mm reference; received components and solder tips require the hand-fit check. |
| Battery | Maximum62x38.5x8.5mm pouch reference, factory protection/wrapper/plug intact. Low supports, broad keepers, no screw or foam pressure into pouch. Factory cable excess uses the centre bay. |
| Microphone | Blue SPH0645, original bottom acoustic port/offset seal. Low-profile insulated joints and SEL jumper, compatible transverse-exit plug. |
| Speaker | Original40mm unit, frame rotated45deg; diaphragm/magnet unloaded by keepers. One-piece shortened non-battery harness removes inline splices. |
| Four switches | Nominal purchased proxies retained. Actual assortment terminals/force/travel must be checked with continuity and centre/edge presses; CAD does not establish those electrical events. |
| LED | Original Kingbright part; formed insulated leads and one keeper. Physical LED lead order differs from J8 order; use the harness table. |
| RF | Original150mm coax, MHF I plug and antenna retained. Rear route has R5 design bends,1mm lateral and0.3mm normal dressing allowances. RF performance and adhesion remain tests. |
| Fasteners |22 total. Flat supported internal head seats, documented lengths, no screw used to pull an interference shut. Actual thread-forming/tapping method and seating torque require process coupons. |
| Soft stock | Retain functional acoustic seals, contact/backing pads, dielectric and grip/grille films. Four PCB pads replace eleven separately handled pieces. Installed thickness includes adhesive. The assembly index lists every included stock group and its installed geometry. |
| Cable restraint | Keep wires inside the open dressing volumes. Use thin nonconductive removable tape on stationary lands, away from joints, seam, optics and moving controls; total tape thickness<=0.10mm. RF route requires two soft restraints at the rear; verify their formed placement with the first article. No new rigid clamp or hidden snap is introduced. |
| Temporary supports | Slicer-generated supports are not modeled product parts. Compare cleanup against the supplied bare-shell views; retain platforms, screw bosses, guide beds and switch seats. |

## Complexity comparison

| Item |28.4|R3.7 candidate|
|---|---:|---:|
| Printed identities |28|21|
| Screws |32|22|
| PCB pad pieces |11|4|
| Loose switch cradles |3|0|
| Separate volume capture rails |2|1|
| Custom battery adapter boards |1|0|
| Adapter-only pads / grommet |5|0|

The microphone’s specified KR-D cable and the revised clear light guide are new fabrication requirements. The lower part count does not eliminate those tasks.