NIMBUS 1 - PROTOTYPE CASING PACKAGE rev0.7 FINAL (2026-08-09)
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Canonical decisions & full history: "Nimbus Unit 1 - Enclosure, Power & Order
Brief" on The Cloud. The package zip is the complete vendor/engineer handoff.

SHELL rev0.7 EXACT PARAMETERS
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Envelope 220 x 220 x 100 mm - corners R26 - top edge R7 - bottom rim R3
Walls 4mm (above z=8) / 6mm below z=8 forming plate socket ledge
Cloud mark: smooth-spline deboss 0.5mm deep, 80mm wide, top center
Rear aperture 168 x 48 mm tangent-to-tangent, z 26-74
4x M4 rear post pilots at (+-76, z 19 & 81)
4x integral corner columns: 14mm wedges at (+-99,+-99), z 8-96, SMOOTH rails
4x M3 foot threads at (+-96,+-96), 14mm deep, in column feet
Socket: opening 208.0mm; plate/net 207.2mm (0.4mm/side); seats at ledge z=8
VERIFIED: volume 510.9 cm3 - probe audit 13/13 - DXF entity audit passed
(1 outline polyline / 72 lines / 72 arcs / 4 circles)

ASSEMBLY (no tools inside cavity, ever)
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Sled (engineer part, bent 5052): channels lined 1.5mm silicone, slide down
columns. Face-down: net/plate nests in socket; 4x M3 up through
net -> washer -> sled flange -> washer -> column foot. Rubber-cap heads = feet
(protrude ~2mm below rim; rim floats). Full elastomer chain: board grommets ->
lined channels -> washered joints -> rubber feet.

SLED REQUIREMENTS (engineer)
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Mini-ITX standard standoff pattern (modularity law: shell outlives the board).
SSD/fan/PSU each swappable without disturbing others. Slotted PSU bracket.
92+120mm fan patterns. Clip antenna mounts. Screws+connectors only.
Channel inner dim = 14mm column + 2x1.5mm liner + fit clearance.

AIRFLOW / POWER
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Bottom in (net or plate slot ring) -> 120mm fan -> rear out.
Draw @120V: idle ~0.1A - typical 0.5-0.9A - full ~1.3-1.4A - peak ~1.7A.
150-170W sustained design point at 35C ambient, 400W PSU (2x headroom).

GATES BEFORE PRECISION METAL
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Donor bench measurement -> 3D-printed fit gate -> anodize coupons
(Blue Box blue vs storm navy + gloss-in-recess mark) -> vendor first article.

OPEN ITEMS (owned/gated, none blocking orders)
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1. Sled fab-final CAD - engineer, after donor measure
2. Headless Wi-Fi onboarding spec - MachineSync (Ethernet-first Unit 1)
3. Radio-through-shell RSSI test - validation week 1
4. Anodize coupons + mark gloss method
5. Dedication etch artwork + serials - at plate production