# MORLOK BC1 assembly and fit guide

**HISTORICAL METAL-DECK ASSEMBLY REFERENCE.** The R2/PC1 body geometry and quantities remain the preserved 37-piece body candidate. PF1 supersedes the metal deck for the current stationary build. Do not follow the old deck fabrication or drilling sequence. Use the [current design guide](https://morlok-robot-lab.morlock.chatgpt.site/current-design/) and [PF1 frame plan](https://morlok-robot-lab.morlock.chatgpt.site/print-plan/). Original source archives are preserved unchanged.

Unchanged R2 and PC1 outer-enclosure candidate. Physical tests NOT RUN.

![Actual CAD assembly](https://morlok-robot-lab.morlock.chatgpt.site/assets/prints/MORLOK_PC1_Assembly_HOLD.png)

## Exact existing candidate quantities

| Geometry | Quantity | Print bounds, mm |
|---|---:|---|
| R2 side panel | 4 | 135 × 120 × 3 |
| R2 plain rear end half | 2 | 108 × 120 × 3 |
| R2 front module panel | 2 | 108 × 120 × 3 |
| R2 lid quadrant | 4 | 138 × 108 × 3 |
| R2 handed corner posts, pp/pn/np/nn | 1 each | 12 × 12 × 120 |
| R2 seam joiner | 8 | 36 × 18 × 6 |
| C01 Standard camera carrier | 1 | 72 × 66 × 5 |
| C02 shutter retainer | 1 | 62 × 48 × 1.6 |
| C03 opaque shutter slider | 1 | 22 × 27.5 × 5.9 |
| C04 camera spacers | 4 | 4.2 × 4.2 × 6 |
| S01 speaker cassette | 1 | 66 × 67.5 × 33 |
| S02 removable speaker grille | 1 | 66 × 72 × 2 |
| M01 removable mic bridge | 1 | 210 × 96 × 18 |
| M02 microphone guard | 1 | 96 × 46 × 2 |
| M03 bridge spacers | 2 | 8 × 8 × 2 |
| **Installed outer-body total** | **37** | **18 STL types** |

The 2 front-module panels replace 2 original R1 plain ends; do not print 4 plain ends as well. Four distinctly handed posts are required. The unchanged optional R2 bare-Pi carrier and 4 spacers are **not** in the 37-piece total, have no assigned chassis position, and are not a CanaKit case mount. Coupons and reference models are not installed body pieces. Never print the assembled visualization as one object.

## What has been verified now

A fresh read-only audit of 32 individual existing STL files passed closed-edge, winding, single-component, zero-area-triangle, positive-volume and bed-contact checks. This includes 18 production-candidate types, 2 PC1 test sections, 2 optional R2 bare-Pi types and 10 TF1 test types. All individual meshes fit within both nominal build volumes.

The earlier PC1 OpenCascade checks passed scoped component intersections, shutter travel, front-panel placement, the nominal 85 mm lid-lift volume and a project-selected USB service corridor. Those checks exclude real cables, hardware stacks, actual received hardware, strength, optics, acoustics and heat. They are historical software evidence, not a new physical result.

The original shell has a 276 × 216 × 123 mm outer envelope, located at Z=3..126 mm above the deck-bottom datum. Individual segmented parts fit the printers; that assembled envelope is not a one-piece print target.

## Printer envelopes and profiles

Official specifications checked 2 October 2026:

- [Creator 5 Pro](https://www.flashforge.com/products/flashforge-creator-5-pro): 256 × 256 × 256 mm. All audited individual parts also pass an 8 mm XY brim allowance by simple bounding-box comparison.
- [AD5X](https://www.flashforge.com/products/flashforge-ad5x-3d-printer): 220 × 220 × 220 mm. The 210 mm mic bridge fits nominally, but an 8 mm brim makes its footprint at least 226 mm wide and does not fit the supplied orientation. The true slicer usable region and purge/skirt settings must be checked. Do not shrink the model to make a printer profile fit.

Bounding-box fit is not slicer, toolpath or machine qualification. Use the exact machine/nozzle/material profile and review all layers, support, brim, cooling and collision warnings before any print. The existing PLA camera-mechanism first-fit is a separate limited test; it does not release PLA for a warm closed electronics body. The earlier PETG shell settings are untested starting guidance, not a qualified process. No temperatures, speeds or material performance are invented here.

## Missing engineering, in priority order

1. **Owned Pi 5 CanaKit package.** Exact case/cooler/HAT variant, actual assembled size, underside lands/feet, vent/fan paths, cable-plug envelopes and service reach. The bare Pi mounting drawing does not define the case geometry.
2. **Power/data cable entry and restraint.** The existing rear panels are vented but have no selected cable pass-through or strain relief. Connector-sized openings must be based on the selected leads, protect cables from edges and preserve access to the approved physical audio disconnect. A plugged-in cable needs bend and hand-clearance space.
3. **Internal placement.** A dimensioned electronics layout with actual wires is missing. A bracket's valid holes do not prove it fits beside the actual kit or future battery. The initial body should be stationary and externally powered; future power and mobility hardware remain separate.
4. **Received PC1 hardware and fasteners.** The Lite official STEP differs from the nominal wiki outline; received revision and both asymmetric holes must be checked. Camera ribbon, optics, shutter opacity, speaker ears/cone gap, USB disconnect, nuts, heads and bridge retention remain unverified.
5. **Structural deck and future running gear.** Metal-deck structural qualification, motor/caster/battery mounts, wheel width/shaft offset/height and caster sweep are not completed. No loaded moving robot, carrying handle or payload claim follows from an enclosure drawing.
6. **Privacy/status controls.** Camera shutter exists. Other selected controls/indicators and a future independent drive-stop mount have no qualified cutouts; reserve removable access without inventing device sizes.
7. **Physical validation.** Seam and nut fits, lid removal, cable pinch checks, heating/cooling, Wi-Fi, acoustics, speaker feedback, camera field of view and mechanical retention all remain NOT RUN.

## Minimum useful measurement return

First send the CanaKit case/cooler model or clear photographs of the assembled kit and ports. For a final internal layout, use the accompanying measurement worksheet: case/cooler L × W × H, actual plugged-in lead extents, fan/vent directions, mounting/foot positions and required service clearance. Do not give a case hole pattern based on an unrelated online enclosure.

The adjustable-mount concept should locate the measured case on a removable tray with replaceable side guides and non-conductive retention that avoids vents, controls and connectors. Tray-to-metal-deck attachment must remain a separate verified interface. Clamp range, retention force, pad material and hole coordinates stay unset until the worksheet is complete. This paragraph is a concept, not fabricated geometry or a retention rating.

## Assembly sequence after fit gates

1. Check measured hardware against the interface tests. The four named posts are handed: pp is +X/+Y, pn is +X/-Y, np is -X/+Y, nn is -X/-Y. +X is forward, +Y is robot left, +Z is up. Origin is the bottom centre of the metal-deck reference.
2. Establish a separately verified metal-deck interface. The source shell post centres are (±129, ±99) mm; these record the shell geometry, not release a drill operation. Insert the posts' inward-facing nuts before attaching them.
3. Fit four side halves, two plain rear halves and two front-module halves loosely. Keep the vents high. Side-to-post axes are world Z=20/105 mm; end-to-post axes are Z=32/93 mm. Never swap those heights or force bolts through misaligned holes.
4. Fit four wall seam joiners inside the shell. Joiner axes are 18 mm apart. Hold the nuts and check that all panels meet without bending. Tighten gently using verified screw stacks.
5. Join four lid tiles with four underside joiners. The resulting lid is one removable service assembly. Undo its four corner screws to lift it off; hold underside nuts to remove one tile.
6. Install the PC1 camera module on the front-view left and speaker cassette on front-view right. Both use the preserved 58 × 58 mm M3 pattern. Follow the included original PC1 README for actual M2/M3 stack checks, spacer orientation and retained shutter.
7. Fit the microphone bridge on the two existing upper front shell/post fastener positions with two M03 spacers. These replace fastener stacks, not add two new shell holes. The nominal lid gap is 2 mm and must be checked physically. The bridge is not a handle.
8. Stop before installing the actual Pi kit until its retention and cables are dimensioned. Do not route a lead across an unprotected edge or close a lid onto it. Measure and verify the actual USB audio disconnect remains reachable.
9. With power absent, verify the real shutter travel, opacity, camera ribbon, speaker grille/cone gap, mic apertures and USB plug reach. Record every physical outcome. Stationary thermal/acoustic/optical/privacy testing follows only after safe assembly; mobility stays separately gated.

## Fasteners without double counting

The preserved shell has 40 nominal M3 screw/nut positions. Two front carriers add 8. Two bridge attachments replace existing upper shell positions and need newly checked lengths; they are not 2 extra positions. PC1 adds 2 speaker-ear M3 positions, making 50 candidate M3 positions, plus 13 M2 positions. The actual nuts, washers, retainers, screw lengths and shopping quantities must follow measured stacks. These are position counts, not a released purchase list.

## Record each physical test

Use Physical_Test_Record.csv. All initial statuses are NOT RUN. A valid mesh cannot establish nozzle bridging, material creep, fit, retention, camera view, privacy opacity, cooling, Wi-Fi or acoustic performance.