Experimental prototype / R3.7 / September 16, 2026
Same case. Connected fit.
Room for the PCB with its connections installed, and fewer small pieces to handle.
Prototype · Physical testing pending. CAD and print exports are checked. Golden remains 28.1 / R3.4.
Original bare case. Exterior, bumper contour, visible controls, openings, grille and seam preserved.
21 product parts + 5 test fixtures. Millimetres; print at 100%. The specified microphone cable and thin harnesses are required for this layout.
Original AI-generated Chalk Ember appearance reference. Select CAD for the actual R3.7 assembly.
Version 28.5 = engineering R3.7. The package and film retain the R3.7 filenames. This candidate follows 28.4 / R3.6, whose printed case fitted the bare PCB but interfered once cables were connected. Publishing this page does not change the CAD.
One matched set. One of each product part and test fixture.
17
Shells, controls, supported retainers and grille bezel.
2
F01 bumper and F02 talk-button grip.
2
L01 lens and L02 periscope light guide.
Walkie_One_R3_7_SEND_TO_PRINT_SHOP_2026-09-16.zip
ZIP · 12.9 MB
17 rigid, 2 flexible and 2 clear optical product parts. One of each test fixture. STL and STEP are alternatives, not duplicate quantities. Millimetres; 100% scale.
SHA-256: 2e8901f170e60a0264fefafce8a8512f4092b673a088114ce0bd9bc6c36314e400_START_HERE_PRINT_SHOP.txt
TXT · 4 KB
SHA-256: 5ed028fd20657d16b2e8cdb6202a97ff698f8152181249629627700ac84b377aPRINT_SCHEDULE.csv
CSV · 6 KB
SHA-256: be8d4b24280a94bf5826296e16bcfc6a6ce143ccd0ca09c4350cb7c5378f027fSHOP_BUILD_RECORD.txt
TXT · 1 KB
SHA-256: 129397a28c442acfc87022d35e48f5f05110d7e3762567e681a518e27efdcf57The ZIP separates the three material groups and five test fixtures, with individual STL files and matching STEP alternatives. Print either format once per item. It also includes clean reference images and owner assembly instructions. Temporary supports are chosen in the slicer; use the front/rear shell diagrams to identify permanent features before removal.
Record the shop’s material, orientation and finishing. Use the supplied joint, battery, PTT and screw-pilot fixtures to check this print process. No printer profile or G-code is supplied.
Compared with 28.4: 28 → 21 printed parts · 32 → 22 screws · 11 → 4 PCB pads.
Connected PCB
The PCB moves and tilts inside the existing shell while retaining the USB opening. Plugs, insulated joints, bends and wire-dressing space are included together. Four paired pads support the board, and a broad stop takes connector insertion loads.
Battery
The custom battery adapter, cover, grommet, pads and fasteners are removed. The untouched factory plug goes to J2. Low locators and broad removable keepers retain the 62 × 38.5 × 8.5 mm maximum battery body; a central bay reserves room for the factory lead slack.
Controls
Three loose switch cradles become supported seats in the shell. One removable volume rail captures two independent sliders with their own stops. The broad PTT and play mechanisms remain; short separate PTT guides leave the wiring corridor open.
Speaker and microphone
The speaker rotates 45° around its unchanged acoustic centre. Two short keepers retain access, with a shorter recessed upper screw. The blue SPH0645 microphone has an open keeper for its low-profile joints and channel-select jumper.
LED and optics
The LED sits beside the PCB. A clear periscope light guide carries light to the original lens. Both optical parts need clear material and suitable finishing; opaque prints can check fit but cannot qualify the indicator.
Antenna and soft stock
The antenna uses its factory adhesive on a thin dielectric carrier, removing two clamps, four screws and old end pads. PCB pads reduce from eleven to four; three obsolete switch-cradle backing films are removed. Adhesive and soft-stock thickness remain specified.
Every retained, integrated, combined or removed part has a recorded disposition. The review also covers fasteners, purchased components and installed stock, with 156 feature-level risk entries.
Prepare the harnesses before assembling the print.
Use the JST 05KR-D6S-P transverse-exit PH-compatible plug, professionally IDC-terminated with 26 AWG, 7-strand UL1061/UL1571 wire, 0.9–1.0 mm outside diameter. The design uses its 9 mm catalog mated envelope. A tall upright PHR-5 plug or a different housing does not represent this layout.
The speaker, buttons and LED use shortened flexible 28 AWG UL1061 wire, 0.8–1.0 mm outside diameter, with the specified PHR housings and SPH-002T-P0.5S contacts. Keep the battery and RF factory cables intact. No main-PCB solder changes or battery-adapter board are required.
Continuity-test every harness and verify switch terminal pairs before connection. LED J8 pins [1, 2, 3, 4] map to physical LED leads [1, 4, 3, 2]. Initial wire blanks include termination allowance; dress the destination end before final trimming.
03_Harness_Instructions.md
MD · 7 KB
SHA-256: 095ecb18bca51b09536fe88f1747e488c43bb68802188a681fed90597e7cc731Harness_Lengths.csv
CSV · 2 KB
SHA-256: 710961bee766b7a47b60cb08f53278a5e2b89bce867b3549320ff92d5f29237c02_Hardware_and_Stock.md
MD · 3 KB
SHA-256: 64e6b0453d5ca39f01d390df2f1a2f4f853af2e280339d5d789a9b7d0150f7e14 min 32 sec · Narrated CAD walkthrough · English captions.
Actual CAD, assembly photos, internal sections and an exploded view explain R3.7. The film distinguishes completed digital checks from physical testing still to come.
Walkie_One_28_5_R3_7_Chalk_Ember_Explainer.mp4
MP4 · 14.9 MB
Actual CAD in the light Chalk Ember finish, with narrated reasoning and remaining physical checks. R3.7 geometry and narration are unchanged.
SHA-256: d50b3433ea3de6bf5e9f6ae7330a6d1eeb0a91a10826dec56a8260afd23b4b73Transcript.md
MD · 6 KB
SHA-256: 39081af882fde9fa3bcfdb3abfc0195cf544bfa9104feb6c458c4a0213a9c345Geometry and assembly evidence for the prototype.
These results depend on documented connector, joint, stock and wire envelopes. Local load calculations are diagnostic screens, not process-specific strength certificates. CAD clearance does not establish print strength, cycle life, sound, light output or radio performance.
SUMMARY.md
MD · 4 KB
SHA-256: 42fb5f00af1716d4a2bdc17860e7e558806b22a73a79c89b6c64d2af69889e31FINAL_VERIFICATION_SUMMARY.json
JSON · 14 KB
SHA-256: b1c7feb43fbdc017bc6c80c83eb6b3388e4aac1a9236e1c227cf4485900558dfSHA256SUMS.json
JSON · 60 KB
SHA-256: 301ddbfd319440fc437678b51c3f9090daef0c291b083b901d56eda3d1638432Use the R3.7 set together. Original engineering filenames and file checksums are preserved.
Walkie_One_R3_7_SEND_TO_PRINT_SHOP_2026-09-16.zip
ZIP · 12.9 MB
17 rigid, 2 flexible and 2 clear optical product parts. One of each test fixture. STL and STEP are alternatives, not duplicate quantities. Millimetres; 100% scale.
SHA-256: 2e8901f170e60a0264fefafce8a8512f4092b673a088114ce0bd9bc6c36314e4Walkie_One_R3_7_Complete_Connected_Prototype.zip
ZIP · 81.8 MB
Matched native CAD, reference assembly, print parts, fixtures, illustrated review, harness and assembly instructions, risk register and verification. Video downloads separately below.
SHA-256: 6387dad9baa2ef35de0046c0a80e0b48e65ec12b8d4d751955c1e05e234a7ef4Use individual parts for printing. The full STEP is an engineering reference containing purchased components and clearance gauges; its external USB gauge is intentionally retained.
Walkie_One_R3_7_CONNECTED_PROTOTYPE.f3d
F3D · 25.8 MB
All 21 print identities verified after reopening. External USB fit gauge is hidden by default.
SHA-256: d30d6361475e1dc4f05b8d3b75075447bdfb24225c97ca03fd1d41af474e8ac9Walkie_One_R3_7_FULL_CONNECTED_REFERENCE_NOT_FOR_SLICER.step
STEP · 119.4 MB
Engineering inspection only. Includes electronics, wiring, stock, clearance reservations and the external USB fit gauge. Do not slice this assembly.
SHA-256: b316ba889488dd53022f851e15224f81a4662132a95ead773fb105db7f0a8fedR37_P01.stl
STL · 3.7 MB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 46de503d31a72f23acacd23633d12368c5984b7b2e84b62799c9dec649fd5447R37_P02.stl
STL · 2.4 MB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: d5ec4dd6d796c25823f7516292b2879df0b184b396e7f06d682bd849a66cf470R37_P03.stl
STL · 169 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 1744324f27582b2a1b35dbf9d25d0d0f57a4aba34d0915bc5757fa30ea20b9b2R37_P04.stl
STL · 328 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: d492a5d93f16888dcc8104186d458d1c89cc478bdccd3e927e0eebdb1f86814dR37_P05.stl
STL · 115 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: b3d5d41dd29fe18902c03624fcde4b687c3267529447c153612e5ebbc780c1a8R37_P06.stl
STL · 177 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 4b6dfc6e94df1db5d664be7af6a9d65da4b4c816fa7d063f8328a4cf347140deR37_P07.stl
STL · 167 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 9fc0845cdcd83d4b2afe3c5e04a0da90f1b208b45b7d276ded5474abf1a6f80bR37_P11.stl
STL · 46 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: c8932f02eb08c69fac147bbe521ea295e7c8a347da81696e0a5a776a4bc53365R37_P12.stl
STL · 64 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 21cc4d16449fdaa8bded21c84eda4fa293e84b3e92decb2d07cbc305e02ee002R37_P13.stl
STL · 269 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 5fd960caf733f73d0b46bd298e576e87e277eeeab003f5c623a7349a92099b25R37_P14.stl
STL · 50 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: a4d71e7175baa008e393c1f463921d59f90ecc82eec7f03e019433e227057b33R37_P17.stl
STL · 140 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 08736339a67f7406edbed44415cc550cada8f87916cb0d9ed0d0f0e9149970abR37_P18.stl
STL · 141 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 841e855168016743aa824055b8056faf1a27c6b4b4e8edde12bf1069182cb384R37_P19.stl
STL · 298 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: cc62e770bdb631be4bf0e90c6d4df829968f39f155f8a1fbe2050185c71aa79aR37_P20.stl
STL · 165 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 63fadb691a020b22b1328bc77b94ba462aff3d4bd178611f2d9eccab7ad51ee4R37_K01.stl
STL · 48 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 9ac7bc31b5eaca087820d053fc3e35c8d2898c8f7eb49291cde7ba96c9f9afe3R37_F01.stl
STL · 846 KB
Flexible material required.
SHA-256: 5909d4000bf66172c0e4b48234f7a4486ff1fd94c7ee84a2680b4089ae5a7092R37_F02.stl
STL · 21 KB
Flexible material required.
SHA-256: baf6ca47b30a0949effc97bf7ff724447ede86c43e77caa249e2d554953a8e22R37_M04.stl
STL · 75 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: a3eca4f08483f1a8aa0304f2d3eec99bae10dd814b8493a4752b88c9d01c7dc8R37_L01.stl
STL · 98 KB
Clear optical material and finishing required; opaque material is a fit gauge only.
SHA-256: 0b0d5587770fdfda5b19524fc8b88e25b3a3f515aff4a88039245bb46c0403d9R37_L02.stl
STL · 8 KB
Clear optical material and finishing required; opaque material is a fit gauge only.
SHA-256: 17b8e9e868b74581737170546af38fbb69d9b09dcac014e58bb7299e1140594dR37_P01.step
STEP · 18.5 MB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 711757047e17c6f15562c5ca4d9d531c05687325edfd89b4bc96eebea2bc27faR37_P02.step
STEP · 8.9 MB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 0abba593fb38f328431f9c0ebc073277b90a740113a892aa84caa0cb7ef367edR37_P03.step
STEP · 185 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 71c8fe40f7a2b2e625f415989c0597f5b091efa4574ca49aba6bb8cf83ecc3dfR37_P04.step
STEP · 729 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 40ec50f9bc6fd16f50a5aa4f60a59929dee06f0d871fefd2ccead225ebbf15c4R37_P05.step
STEP · 323 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 80e74c5fb9451f4d2b6fa9bd92debdfd1268cda0b52757621273612fb3a62094R37_P06.step
STEP · 221 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: c2fde844a6db18642e150954e2b78ed77069dc3a8655bc463418578d6205fad7R37_P07.step
STEP · 177 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 19b2ddabd80d3866b2f11bdbcf6a7c2d60359d5b473a98e3da88706de86658faR37_P11.step
STEP · 40 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 639b7a02b82cc62c8b90b976c3a5fa67c8df16c98a72b25058a25a1d85faca7fR37_P12.step
STEP · 47 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: ce0ced3745ee739f7d4c40d64b17fd40b2085094ff3f5df99665996158567255R37_P13.step
STEP · 620 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: cbe6cf5f7e3306c2197120edd6c32017fa3e4f50d368b2da6173fb7b98a9d5a9R37_P14.step
STEP · 47 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: f954e4fd2fee87af747d46a0eab175fa25c976b682e812f3d236f0505b18412bR37_P17.step
STEP · 180 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: ca2f497e6fa82fd8d581a5f19e04ddc96ebe251a860775681cefbf3d52b5555dR37_P18.step
STEP · 201 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: 6911bbed07fb4314f1b1d1c01eeb9ed402d774e8f54ac337f1a9b88220bc88a2R37_P19.step
STEP · 526 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: e22f5abddbc8cd346490be55fc09a79bd394bdd4bdfecd10fc6a3e7ab6dd23cdR37_P20.step
STEP · 714 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: b2d04cfa0504ddd75829da0a349d43666ddd1ed17a4ed5a1174c69f2df2addb7R37_K01.step
STEP · 201 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: fd3bd4f419c3ce8b3442624b1f5b3207d0a63b5ced4f3f6cd909ee21aecc440dR37_F01.step
STEP · 769 KB
Flexible material required.
SHA-256: 6ed7ae20077877f9bb3e61ea741b13a475f5756276ede232b79d3f56fa155873R37_F02.step
STEP · 33 KB
Flexible material required.
SHA-256: 28e2129ae7e7fc5583ecff3ba5a9d5aa33998dde0b6bbcd261e81e3b48d0fc8aR37_M04.step
STEP · 92 KB
Rigid structural print. Match coupons to material, orientation and process.
SHA-256: ef2bac61fd4e46c80d25a8b4827db8231a14af2ddb8e2e4020ff4ca0146e3ebdR37_L01.step
STEP · 12 KB
Clear optical material and finishing required; opaque material is a fit gauge only.
SHA-256: bc85eb56e7c0dcc4ed0b700d5c1874cb53d5f3e42d3bd683e2bfe28f35998448R37_L02.step
STEP · 105 KB
Clear optical material and finishing required; opaque material is a fit gauge only.
SHA-256: 7f9a97e0229ad5435c80946c304669f8bc0862ade236112e95076e854cba1b2b01_Component_Review.md
MD · 8 KB
SHA-256: 30e4db6f44acaa3b2c39b1b857ff057b0ff111e61d2db8c164f06be4a1652d8e02_Hardware_and_Stock.md
MD · 3 KB
SHA-256: 64e6b0453d5ca39f01d390df2f1a2f4f853af2e280339d5d789a9b7d0150f7e103_Harness_Instructions.md
MD · 7 KB
SHA-256: 095ecb18bca51b09536fe88f1747e488c43bb68802188a681fed90597e7cc73104_Assembly_and_Qualification.md
MD · 6 KB
SHA-256: 17cc8aa823c7da8635656c26336bebb5980bfffb1210d83c0573a86455731ef505_Feature_Risk_Register.md
MD · 76 KB
SHA-256: 1f5e0abe0f3342869aeb2cac8ffe96ad046d5e49b2971d3ffb61d91ccd8f630806_Structural_Screen.md
MD · 3 KB
SHA-256: f5376dbb61688991e2f76fca0a70ac577284f2af9d86675e4389bc6126ebf62207_Dimensions_and_Sources.md
MD · 4 KB
SHA-256: b1e5b03192476cff12de95f0326c3657dc9eeb25d19b8b2660c1c31e7dc26277Feature_Risk_Register.json
JSON · 292 KB
SHA-256: 86a8836dacd9e325dcf37fc7f15ec4f654d875ad10ed38dd8f9d861d1a578126Harness_Lengths.csv
CSV · 2 KB
SHA-256: 710961bee766b7a47b60cb08f53278a5e2b89bce867b3549320ff92d5f29237cPart_Dispositions.json
JSON · 7 KB
SHA-256: 0537ea52db9b752b3344ffe059737b389f6e8d045e7c3fef1de7f4a273230dcdPhysical_Qualification_Log.csv
CSV · 1 KB
SHA-256: 0a3026f4e9a399a7098bd260fd1e3c7d9bfbd8d47ab10ef39487ccb749117f6aR37_exterior.png
PNG · 349 KB
SHA-256: 253f7a9f278150fcdf9d5f252756eee4f1204f82e960b49a21a1c734bf6fff2eR37_connected_interior.png
PNG · 690 KB
SHA-256: 7dfb47d3ecf20fd859a7f056e3b70b89f78c92b68136178e2779b63771c6e5a9R37_front_mechanisms.png
PNG · 923 KB
SHA-256: f1a57a9fe7052d2997066f29029490942f46063d4b7bb9a0f7db7d1075db7459R37_exploded_major_groups.png
PNG · 421 KB
SHA-256: f561335062f8b6e5bb0ad7c8deea983606475360c7fa747b450dff4a76343eb3R37_front_shell_permanent_features.png
PNG · 545 KB
SHA-256: c187dfafef8bc940693862fcd9113a0657da89cbc9f3c0e974ca6d62b5a25917R37_rear_shell_permanent_features.png
PNG · 401 KB
SHA-256: 2085792e98f50445b25955d5187807e54aa41ebb7063a4ecf7d8cc7c26015e2fR37_internal_sections.png
PNG · 286 KB
SHA-256: 343d926bd11403ecc4ecac38d47cc6f3b57cbaded0bfc2a911c0837970caa421R37_harness_routing.png
PNG · 161 KB
SHA-256: 06951a57cc8ccf3753615d2ed5740b2e7a4e802dfe7a4ab0b3f50f381fde54a8Print → Assemble fully connected → Review
Physical qualification is still pending. Golden promotion is a separate decision after those results.
04_Assembly_and_Qualification.md
MD · 6 KB
SHA-256: 17cc8aa823c7da8635656c26336bebb5980bfffb1210d83c0573a86455731ef5Physical_Qualification_Log.csv
CSV · 1 KB
SHA-256: 0a3026f4e9a399a7098bd260fd1e3c7d9bfbd8d47ab10ef39487ccb749117f6a