# Flight Panel R1 build and acceptance

Build two rows of seven **moving**38-position characters. No position is a fixed insert. Use the current `hardware/redesign/dimensions.json`, the wiring in `ELECTRICAL.md`, and the matching firmware. This checklist is intentionally incomplete until measured on actual hardware.

## Current print inventory

Per moving character,14 total: one original shell, motor gear plate, motor gear, center gear, Hall/wire retainer; one **revised38-hole drum**; and38two-sided leaves. Optional original shims only as actual fit requires.

Each38-leaf set has36unchanged original pairs fromBlankA through89, plus revised9Dash andDashBlank. Omit original9Blank. The entire panel requires532leaves. Import both body and glyph parts in their registered coordinates; do not center each mesh independently. Use the provided multipart3MF for the two new leaves.

Shared row parts:4sandwich plates,4outer covers,8M3rods cut to276.3mm, row hardware in the BOM. Shared carrier: left/right carrier, left/right removable back, left/right foot and concealed underside seam strap. The revisedSTLs are oriented for printing; STEP files and viewer meshes retain assembly coordinates.

## 1. Qualify the printer and new drum

- [ ] Confirm printer, nozzle, filament and color-change method. Re-slice all geometry for that exact machine. Do not send sourceA1Mini G-code to aP2S.
- [ ] Print a small original flap sample and the two new boundary leaves. Confirm the glyph halves, hinge pins and thickness.
- [ ] Print one38-hole drum. Measure hinge holes, center bore and magnet pocket. Nominal hole diameter1.8mm and chord pitch3.8895mm are CAD dimensions, not guaranteed printed values.
- [ ] Dry-fit all38leaves. Hand-turn through a revolution without catching, rubbing or pin strain. Check the narrow magnet-to-hinge wall before inserting the magnet.
- [ ] Confirm shell, gear train, retainer and motor clearances through the complete sweep.

Record printer/profile, material, layer height, measured fit, time and any changes in `evidence/physical-acceptance.md` when actually performed. Do not create fictitious passed results.

## 2. Prove sensing and electronics with one module

- [ ] Identify actual motor/driver and Hall pinouts. Use5V motor, bare digital open-collector Hall,3×1mm magnet.
- [ ] Test both magnet poles and mark the active face before glue. Confirm one clear installed transition per revolution.
- [ ] Wire oneMCP23017 at0x20 with5Vlogic, translatedSDA/SCL/RESET, pull-downs and Hall pull-up. Follow the exact breakout pull-up modification plan before adding the fifth board.
- [ ] Check polarity, resistance and fused power before energizing. Motor current never travels through a breadboard, controller or signal chain.
- [ ] Flash with external5Vdisconnected; unplugUSBbefore restoring external power unless the particular board's isolation has been verified.
- [ ] Use the one-module commissioning profile, calibrate new drum phase, then cycle **all38symbols**.
- [ ] Repeat at least10complete cold-start home cycles and10full symbol cycles. Record jams, repeatability, supply voltage/current and driver temperature.
- [ ] Confirm sensor failure times out, I²C disconnect holds hardwareRESET, and explicit recovery re-homes. Cut power for an actual jam; firmware is not a substitute for electrical isolation.

## 3. Batch verified modules and assemble rows

Only proceed after the first mechanism passes. Every character is identical, including top-center.

- [ ] Produce13additional38-position sets and qualify each individually.
- [ ] Label01–07top row and08–14bottom row. Apply MCP mapping `chip=floor(index/3)`, `slot=index%3` using zero-based index.
- [ ] Deburr and dry-fit8rods at276.3mm. Fit original end hardware. Tighten evenly without binding a drum.
- [ ] Test each row after clamping; remeasure the far-end5Vrail while motors move.

## 4. Assemble the carrier

- [ ] Print the seven current carrier pieces in their exported orientations. Confirm insert pilot fit on a small scrap before installing22totalinserts across row ends and carrier.
- [ ] Slide the carrier halves **sideways around both finished rows**, then join the center seam. The completed rows cannot pass through the rear of the joined carrier because of its integral uprights.
- [ ] Fit the concealed underside seam strap with two M3×8 low button-head screws whose heads are no higher than 1.8mm. The other 12 short carrier screws may be button or pan-head. Fit rear seam bolts and tabletop feet; check fastener clearance, foam compression and stability without relying on friction alone.
- [ ] Dry-fit actual boards, insulated mounts, rated inlet, fuse holders and connectors in the service bay. Generic mounting slots do not prove every purchased board fits.
- [ ] Provide strain relief, insulated terminations and ventilation. Fit backs only after wiring tests.

## 5. Complete-panel acceptance

- [ ] Enable14active modules. All14home, with at most4motors energized together.
- [ ] Display`ORD-LAX` / `UA 1899`, then`WELCOME` / `JOHN   `. Verify top-center changes fromdash toC.
- [ ] Cycle all38symbols at every position. Check each offset independently.
- [ ] Verify latest-target behavior, stop/recover, restart recovery, wrong/stale external input and missing network.
- [ ] Measure worst-case normal current below the planning limits4.8Atotal/2.4Aper row; verify startup transients and fuse behavior. If exceeded, revise the electrical design before use.
- [ ] Record farthest-module voltage, component temperatures and measured effective flip rate during a sustained run.
- [ ] Check tip resistance, cable pulls, cover security, sound and service access. No wall mounting is qualified by this tabletop design.
- [ ] Connect the actual flight-data source and verify route/flight mapping and freshness against that source. The browser demo alone does not establish provider integration.

## Current evidence boundary

CAD solid/interference checks, firmware compilation and software tests can pass before any physical checks. The product remains a prototype until this checklist has measured results. No supplier arrival promise or physical completion date is implied by a planning estimate.