Chuck, Did you rotate the big transformer a little to get a better fit?
The toroid is wound with big wire, which overlaps. This creates the irregularities you see. 73 de Bob, K6XX Chuck - AE4CW <[email protected]> wrote: >Well, here what I discovered that is causing or contributing to the top cover >protrusion (at lease in my case): >1) My power transformer is not symmetrical. It is thicker on the z-bracket >side and thinner on the left side. When the nut is tightened, the metal >disk leans to the left causing the bolt to also lean to the left. The head >of the bolt put a twisting moment on the bottom cover causing the left front >corner to be bent slightly down. This then pulls the left side panel down >which now causes the front panel to also droop slightly on the left side. >Now all of this is a matter 20-30 thousands of an inch, so it's certainly >not huge but enough to contribute to the protrusion. >2) The very top/front edge of the Z bracket protrudes several thousands of >an inch above the folded over portion that contains the screw bosses. So, >tightening the front/middle cover screw actually causes the front cover to >be pushed up slightly at the edge. I think this is a manufacturing defect. > >Here's what I've done so far. >1) After loosening the transformer I straightened the slight bend in the >bottom cover by putting a shim under the left side panel and pressing down >with a blunt tool on the bottom cover just in front of the transformer. >2) I put some plastic shims under the metal disk on the thinner side to >allow the plate to remain level and the bolt perpendicular as the nut is >tightened. There is still some distortion of the bottom cover when the nut >is tightened to 55 in-lbs. I believe the extra plate on the bottom is >intended to remedy this, but there is still some distortion. > >After all this there is still some protrusion but about 1/2 as much as >before...the total in the middle is about 30 thousands while the edges are >about 10 thousands. So the middle is about 20 higher than it should be. > >BTW, the z bracket by itself is not at fault (other than the slight defect >at the top/front. It's actually about 8-10 thousands shorten in the front >than the rear. So, bottom line, as best I can tell, the bottom cover >distortion caused by tightening the transformer bolt is the main culprit. >Once again, this is NOT a big deal but just not quite up the the "fit and >finish" standard that Elecraft is well known for. I'll give the folks in CA >a call next week to see what advice they have. >--- >Chuck, AE4CW > >-- >View this message in context: >http://elecraft.365791.n2.nabble.com/KPA500-Z-Bracket-Top-Cover-tp7275169p7277027.html >Sent from the Elecraft mailing list archive at Nabble.com. >______________________________________________________________ >Elecraft mailing list >Home: http://mailman.qth.net/mailman/listinfo/elecraft >Help: http://mailman.qth.net/mmfaq.htm >Post: mailto:[email protected] > >This list hosted by: http://www.qsl.net >Please help support this email list: http://www.qsl.net/donate.html ______________________________________________________________ Elecraft mailing list Home: http://mailman.qth.net/mailman/listinfo/elecraft Help: http://mailman.qth.net/mmfaq.htm Post: mailto:[email protected] This list hosted by: http://www.qsl.net Please help support this email list: http://www.qsl.net/donate.html
