Build from the parts you have

PARTS Reference M3 kit or verified equivalent, one loose test screw and matching nut; tolerance coupon if available.

TOOLS Millimetre ruler or calipers; hand hex keys; small tray for loose nuts.

FASTENERS M3 × L socket-cap, where L is the measured under-head length. Do not choose a length from head size.

1. Sort by the box labels. Check one screw from each compartment with the ruler or calipers; measure from the underside of the head to the tip.

2. Start a matching loose nut on the screw by fingers, away from the robot. It should run freely without being forced. A socket driver must fit the head securely; the exact included key size is not confirmed here.

3. Measure the actual nut across its flats and its thickness. Measure any proposed flat washer’s outside diameter and thickness. Keep split lock washers separate; they are not automatically part of every plastic joint.

4. Use the joint-specific callout in the next steps. A screw must reach through the nut’s full threaded thickness without a harmful tip projection or bottoming out.

PARTS R2_post_pp, pn, np and nn, one of each.

TOOLS Paper labels, ruler and a flat table.

FASTENERS None for this identification step. Each completed post ultimately has side/end M3 fasteners plus one top and one bottom M3 attachment.

1. Mark the robot’s front as +X. Looking down with front at the top of the diagram, match each post to pp (+X,+Y), pn (+X,−Y), np (−X,+Y) and nn (−X,−Y).

2. Find the open inward nut-access features. The two external panel faces must face the matching outer walls; do not rotate a wrong-handed post until it merely looks close.

3. The side-wall screw levels are 17 and 102 mm above the post bottom. The front/rear panel levels are 29 and 90 mm above the post bottom. Their different heights identify the two faces.

4. While the post is accessible, test the actual M3 nut in each upper and lower inward side slot. These are 9.6 × 6 × 2.8 mm rectangular openings, not hex recesses. It must enter and come out without force.

5. Label each post on removable tape. Keep any shortened test post separate. Remove unsupported nuts after the fit check, and install/support them when their top or bottom screws are fitted.

PARTS One full R2_side, one matching front or rear half, and the correctly handed post.

TOOLS Flat support, ruler, calipers and hand hex key.

FASTENERS Four M3 positions at this corner. M3 × 16 socket-cap is the first catalog comparison for ordinary wall/post joints (H01); final fit depends on the actual nut, washers and tip clearance.

1. Keep the post upright and support it. Put the 3 mm side panel against its outside face with vents high. Align the two side holes at post-local heights 17/102 mm.

2. Offer the front/rear panel to the other outside face. Its two post holes are at local heights 29/90 mm. Do not swap these with the side-panel heights.

3. Check the inward-facing M3 hex pockets without driving a nut into them. R2 nominal pocket width is 5.7 mm across flats; the side-pocket actual recessed depth is 2.7 mm.

4. With a compatible nut seated and visible, compare the actual screw length against the joint stack. Insert by hand only after the path, head support and tip clearance have been checked. Leave the fit loose.

PARTS Four R2_joiners for walls; paired side, front and rear halves as available.

TOOLS Flat table, hand hex key, small nut holder and calipers.

FASTENERS Eight M3 positions, two per joiner. Compare M3 × 10 socket-cap (H03): the CAD seat span is 6.3 mm before the nut and washers; safe projection still needs checking.

1. Place two matching panel halves edge-to-edge on the table. Their exterior surfaces are aligned; each seam hole lies 9 mm from the mating edge.

2. Put one joiner across the inside of the seam. Its hole centres are 18 mm apart, matching the two panel seam holes. The flat joiner face meets the panels; hex recesses face inward.

3. Seat the two measured M3 nuts gently in the accessible recesses. Compare each screw’s under-head length with 6.3 mm plus washer thickness plus the actual nut thickness; also inspect where the tip will end.

4. Start both screws by fingers, keep the seam straight and only remove looseness after the two surfaces lie naturally flat. Repeat for the other three wall seams as parts become available.

PARTS Four handed posts; four side halves; two rear halves; two front-module halves; four wall joiners.

TOOLS Flat table, temporary supports, hand hex key and ruler.

FASTENERS 16 post-side/end M3 positions plus 8 wall-seam M3 positions. The microphone bridge later replaces two upper-front screw stacks, not two additional holes.

1. Extend the accepted single-corner fit around the body. Keep all vents high and all nut pockets facing the service interior.

2. Use the two panels with 50 × 50 mm apertures at the front. Use the two plain end panels at the back. Each front opening has four M3 module holes on a 58 × 58 mm square.

3. Fit each inside wall joiner. Keep fasteners loose until all corners and seams agree. Support the walls independently while the PF1 frame is unfinished.

4. Check the front view: the camera belongs on the viewer’s left and speaker on the viewer’s right. Label the two openings before fitting modules.

PARTS Four R2_lid quarters and four remaining R2_joiners.

TOOLS Flat table, ruler, hand hex key and nut holder.

FASTENERS Eight seam positions: compare M3 × 10 (H04). Four corner/post positions: compare M3 × 10 or 12 (H05). These are conditional lengths, with different nut-seat spans.

1. Arrange the four roof quarters exterior-face down on the table. Keep their corner/post holes at the outside corners and the two seam-hole systems aligned.

2. Bridge each of the four lid half-seams with an underside joiner, with its flat face against the lid. Align both 18 mm-spaced screw axes before starting either screw.

3. Use the same 6.3 mm nominal head-seat-to-nut-seat basis for each lid seam, then include the actual nut and any washers. Hold the underside nuts during removal.

4. Turn the assembled lid over with support. Slide and support the measured M3 nuts through the four inward X-facing upper post slots, with flats aligned to the 6 mm width; then trial-place the lid. Its corner screws must engage those nuts, not printed plastic.

PARTS C01 camera carrier; four intended M2 nuts if available. No camera required.

TOOLS Good light, calipers and a nonmetallic pointer.

FASTENERS Four M2 camera-board positions at (u,v) = (±10.5, −12.4/+0.1) mm relative to the lens centre.

1. Identify the camera-board holes close to the optical opening. Do not confuse them with the four M2 retainer holes at (±20,±20) or the four M3 shell holes at (±29,±29).

2. Inspect each nominal 4.4 mm-across-flats, 1.8 mm-deep M2 nut pocket from the front. The lower two and upper-left positions are partly overhung.

3. Leave the carrier unmodified. Do not force, melt or cut the rails to insert a nut, and do not assume a nut that fits once seated has a usable insertion path.

4. Record the carrier revision and this straight-insertion obstruction. No alternative tilted route has been validated. Continue with the independent shutter dry-fit and other modules while the camera-board fastener path is resolved.

PARTS C01 carrier, C02 retainer and C03 slider. T01 is optional as an initial local test.

TOOLS Clean flat table and ruler.

FASTENERS No screws needed for the supported dry-fit. C02 later uses four M2 fasteners, separate from the camera board.

1. Place C01 with the shutter guides facing up. Inspect the guide surfaces for loose debris, warping or obvious print damage.

2. Place C03 in the guides with its grip toward the retainer’s finger slot. Support C02 gently above it in its designed orientation; do not press down to make a warped part fit.

3. Move the blade slowly through its nominal 24 mm travel. Closed places solid blade across the opening; open clears the opening. Stop at binding or contact with a rail.

4. Lift off the unsupported retainer and keep the parts together. Record travel, binding and any visible rubbing. Do not call a visually solid blade proven optically opaque.

PARTS C01–C04; four C04 spacers; actual Camera Module 3 Standard; matching front shell panel.

TOOLS Calipers, small hand driver and a supported parts tray.

FASTENERS 4 M2 camera-board + 4 M2 retainer + 4 M3 carrier-to-shell positions. None of the M2 hardware is supplied by an M3-only kit.

1. After Step 07’s hold and the actual screw-stack checks are resolved, verify the actual camera is Standard. Offer its mounting pattern to the carrier without loading the lens, connectors or components.

2. Put one 6 mm C04 spacer at each of the four PCB mounting lands. The camera screws enter from the PCB rear toward the carrier’s captive nuts. Include actual PCB thickness and any approved washer in the length calculation.

3. Before the blade is retained, confirm every camera screw tip remains below the moving blade’s underside. Do not choose a longer screw simply to get more protrusion.

4. Fit C03 and then C02 with four separate M2 fasteners at (±20,±20). Attach the complete carrier to the front-view-left shell opening with four M3 fasteners at (±29,±29), supporting inside nuts.

PARTS S01 cassette, actual Seeed 114993346 speaker; T02 support section if present.

TOOLS Calipers, hand hex key and nut holder.

FASTENERS Two M3 ear bolts; compare M3 × 25 socket-cap (H08). Heads load from the rear into 6.2 mm-diameter, 3.2 mm-deep recesses. Actual heads, nuts and tip clearance must fit.

1. Check the actual speaker’s two ear-hole centres against the nominal 57.5 mm pitch. The printed ear passages have 1.2 mm slot travel; do not bend an ear to compensate for a mismatch.

2. Use T02, if available, to check whether the actual socket-cap head seats fully in the rear recess. A head protruding beyond the cassette’s panel-contact face will prevent seating.

3. Insert the two ear bolts from the rear before the cassette meets the shell. Set the speaker ears on the supports; route the lead freely through the central opening.

4. With the actual ear and any approved washer in place, select length from the measured stack. Start the front nuts by fingers and inspect full engagement without pulling or distorting the ear.

PARTS S01 with speaker, S02 grille and the front-view-right module panel.

TOOLS Hand driver, nut holder and calipers.

FASTENERS Four M3 through-bolts on the 58 × 58 mm module pattern. Nominal front-head-seat to shell rear is 38 mm, before nut/washer allowance.

1. Offer S01 to the front-view-right aperture and confirm the two recessed ear-bolt heads are below its rear mounting face.

2. Place S02 on the four column ends with its four corner holes aligned. Check the speaker face is clear of the grille; the CAD body-plane gap is 3 mm, not a cone-motion qualification.

3. Compare the complete stack to the available screw length. A 30 mm screw cannot cross the nominal 38 mm stack and engage a nut. Keep this assembly supported and unfastened until correct longer hardware is selected.

4. Once qualified bolts are available, insert the four from the grille front, support the interior nuts and start all four before taking up looseness. Confirm later service removal does not pull on the speaker wire.

PARTS M01 U-bridge, M02 guard and actual USB-only reSpeaker Lite board.

TOOLS Calipers and a small hand driver.

FASTENERS 2 M2 board positions and 3 M2 guard positions. These use 2.4 mm printed clearance passages; exact lengths and head clearances remain open.

1. Compare the board to the design before mounting. The supplier wiki says 86 × 35 mm; the source STEP PCB is about 82.024 × 34.007 × 1.51 mm. Do not scale the printed mount or invent a four-hole pattern.

2. Orient the microphone-bearing underside toward the front; the component-rich side faces rearward. Confirm both asymmetric holes naturally match the two support axes.

3. Offer M02 without fasteners. Check the two microphone openings, shared button slot and indicator window against the actual board. The USB edge must remain open.

4. Only after that fit agrees, record the two board-fastener stacks and the three separate guard stacks. Use measured M2 hardware with safe board lands and no component contact.

PARTS M01 assembly, two M03 2 mm spacers and the two upper-front shell/post positions.

TOOLS Hand driver, nut holder, actual USB plug/cable and ruler.

FASTENERS Two replacement M3 bridge bolts at Y=±99 mm; compare M3 × 25 socket-cap (H02). They replace existing upper-front bolts. Check the full actual stack before use.

1. Support the bridge independently. Remove one upper-front shell/post screw at a time while holding its nut. Keep the shell supported.

2. Place one M03 spacer between each bridge foot and shell. Align the bridge’s 198 mm-spaced mounting axes with the existing upper-front post axes.

3. Recalculate the original end/post screw stack with the added 2 mm spacer and 4 mm bridge base. Select a compatible longer M3 screw only after the actual nut and tip clearance check.

4. Dry-check removal and replacement of the complete lid, then actual USB plug insertion and unplugging. Keep the cable relaxed and reachable without pulling the PCB.

PARTS FT01 and FT02 test halves; one extra F05 splice.

TOOLS Flat table, light and millimetre ruler.

FASTENERS None for this first alignment check. Frame joints ultimately use M4; the M3 kit does not qualify them.

1. Find and inspect both ribbed sample halves. Confirm each physical part is present, undamaged and identifiable; do not treat two filenames as two completed parts.

2. Place F05 underneath the halves with its hexagonal nut pockets facing down. Put the ribbed sides of FT01/FT02 up.

3. Keep the designed central seam, nominally 0.4 mm. Let the pieces sit naturally on the splice; do not squeeze the seam closed.

4. Look down through all four axes. Record whether the holes agree and both samples sit flat. Leave the test unloaded and without screws at this stage.

PARTS F01, F02, F03, F04 and four accepted F05 splices.

TOOLS Flat table, ruler and calipers.

FASTENERS 16 M4 splice positions: four per splice. Candidate holes are 4.4 mm; underside pockets are nominal 7.5 mm AF × 3.5 mm deep.

1. Proceed only with accepted full quarters. The FT01/FT02 test halves do not replace F01–F04.

2. Arrange F01 front-left, F02 front-right, F03 rear-left and F04 rear-right, ribs up. Preserve both nominal 0.4 mm centre seams.

3. Position one F05 under each half-seam. Its four bolt axes must match the adjacent quarter holes; nut pockets face down and must remain accessible during fitting.

4. Trial-seat the actual M4 nuts and check one complete splice stack before repeating it. Use the frame length equation in the joint schedule; M4 bolt lengths are not supplied by the M3 kit.

PARTS F06 ×2, F09 ×4, F08 ×4 and F07 ×1 with the accepted full base.

TOOLS Flat table, straightedge, calipers and appropriate hand tools for actual M4 hardware.

FASTENERS 4 shared M4 crossmember/foot bolts and 4 M4 tray/riser bolts. These are two different stack lengths, not eight identical bolts.

1. Place front and rear F06 crossmembers on the upper rib plane. Position the four F09 feet below their matching attachment axes.

2. Fit the shared through-bolt path through each crossmember/base/foot stack only after its dimensions are recorded. Check underside nuts and tips remain within the foot recess, so all four feet can sit flat.

3. Place four F08 risers at the tray axes, then offer F07. Check each hole, slot and tool path before selecting the four tray bolts.

4. Keep the tray empty. Its 180 × 140 mm envelope does not establish that the actual CanaKit case fits or is securely retained.

PARTS Accepted shell and PF1 base; actual case only for external measurement, not installation.

TOOLS Support blocks, calipers and ruler.

FASTENERS Four M3 post-to-base positions at X=±129, Y=±99 mm; compare M3 × 25 socket-cap (H06). Already included in the shell count; the actual new-frame stack must pass.

1. Support the body over the empty base. Align its four post centres with the PF1 shell axes; do not use the old metal-deck drilling instructions.

2. Check all post bottoms contact the intended rib plane. Insert and support the measured M3 nuts in the four lower inward post slots while the lid is off. Stop if a slot or tool path is inaccessible.

3. Calculate the new bottom-attachment length from the PF1 base and post nut-seat stack. A historical metal-deck screw length cannot be assumed to fit the thicker printed frame.

4. Measure the actual CanaKit case, cooler, vents, feet and plugged-in cable envelopes separately. Leave case restraint, pass-throughs and strain relief pending until their geometry is established.