Core Rear Mount Fit R1.

Research record

The detail behind
the study.

Source-linked work for this revision. Reported checks describe the stated model or test; physical qualification and applicability to the current retrofit remain separate.

Core rear mount: prototype fit budget R1

R7 passes nominal geometry checks, but all three examined sliding fits fall below the proposed prototype clearance targets after dimensional variation and coating. This analysis does not change the CAD or authorize fabrication.

The head and slot calculations subtract half the opening/member size stack, 0.10 mm relative center error, 0.05 mm carrier coating and 0.025 mm stud coating. The axial calculation subtracts both dimensional tolerances and coating on both opposing faces of each component. No statistical cancellation is assumed.

These are proposed budgets for a machined prototype, not demonstrated process capability. Relative center error is an assembled-pattern allocation; individual stud location, hole location, rotation and fixture error must together remain within it. Burrs, form error, thermal movement, dirt and elastic deflection have no additional allowance here. The positive residual gap therefore does not prove reliable assembly or outdoor service.

Under these exact assumptions, entry diameter and slot width each need at least 0.03 mm additional size, and the stud neck needs at least 0.15 mm additional length, merely to reach the proposed targets. The next geometry revision should include reserve and recheck wall clearance, thread engagement, stud retention and the complete release path. Changing the neck cannot be treated as an isolated dimension change.