Hi Mike and all,
I seem to remember many years ago when I was building K2 #402 that there is
some play in the connections for the case as the panels are put together. I
think that I had the same problem that you have. The slop in the
connections is required so the screws will always enter the panel holes, but
if things aren't kept in alignment the resulting box can end up a bit
warped, as the slop in each hole can add up to a significant variance when
the box is complete.
I think I took the case apart and when I reassembled it I built it on a flat
surface. I tried to make each joint match up as best I could as I added the
bottom, sides, front panels, etc. I think the test as to whether the case
is in good alignment is when you attach the top cover as the last piece.
All the corners of the top should line up perfectly with the other panel
corners. Sometimes I had to loosen the other two screws on the silver
connector bars and sometimes another panel completely to get everything to
match up.
Once the case is aligned I was always careful to consider which panel to
remove when servicing the unit. Taking to top panel off is always easy, but
if you take another panel off afterwards like a side panel, you will have to
be sure the two are properly aligned with each other and to the other panels
when reassembling the case. I don't know if this has ever been fully
addressed before.
I hope this helps, and I hope this doesn't sound like I am a nut. ;o)
Regards,
Steve Pituch, W2MY
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