3. Chassis Assembly
This section will guide the operator through the step-by-step process of assembling the main trap chassis, which forms the structural core of the T.R.A.P. system.
3.1 Parts List
Before you begin, ensure you have the following components and complaints are prep:
- Universal Mounting Plate (2x Socket Button Head #6-32 x 7/16”)
- Chassis Base
- Chassis Track Base (1x Flat Head #4-40 x 1/4” and 2x Flat Head #4-40 x 1/2”)
- Chassis Track Guides (4x Flat Head 4-40 x 7/16” and 4x Flat Head 4-40 x 5/8”)
- Right Wall (5x Flat Head 4-40 x 7/16”)
- Left Wall (5x Flat Head 4-40 x 7/16”)
- Rear Wall Assembly (4x Flat Head #4-40 x 7/16” and 1x Socket Cap #4-40 x 1/4”)
- Release Lever (1x Socket Cap #4-40 x 7/8” and 1x Nut #4-40”)
- Lock (1x Spring and 1x Socket Cap #6-32 x 1/4”)
- Rear Handle Cap (4x Flat Head 4-40 x 1/4”)
- Front Handle Cap
Tool Bits:
- 1/16" hex bit
- 5/64" hex bit
- 3/32" hex bit
- 7/64" hex bit
4.2 Assembly of the Chassis Base and Track Guides
Base Plate Orientation and Fastening:
Lay the Chassis Base (Item 2) on top of the Universal Mounting Plate (Item 1).
Crucial Orientation: Ensure correct part orientation. The single hole closest to the edge on the Chassis Base indicates the rear and must align with the U-shaped notch at the back of the Universal Mounting Plate.
Next, place the Chassis Track Base (Item 3) on top of the Chassis Base. This plate's orientation is also critical; when aligned correctly, it will sit flush with the front edge of the Chassis Base.
Securing the Base Layers:
Using a 1/16th hex head bit, Secure the stacked layers (Chassis Track Base / Chassis Base / Universal Mounting Plate) together using the three center screws.
Use the 1x Flat Head #4-40 x 1/4” screw in the center hole.
Use the 2x Flat Head #4-40 x 1/2” screws on the sides (one per side).
Installing the Track Guides:
The Chassis Track Guides (Item 4) are installed in two layers. The middle (smaller track) goes on first, then the larger track goes on top of it.
Orientation is Critical: Both sets of track guides have a radius (rounded edge) on one side. This radius must be positioned at the front of the trap and point inwards toward the center of the chassis.
The track guides are mounted to the Chassis Base using the following fasteners:
Use 2x #4-40 x 5/8” Flat Head screws for the middle (smaller track) holes.
Use 2x #4-40 x 1/2” Flat Head screws for the outer (larger track) holes.
Flush Fitting (Important Note):
All Flat Head screws used in this base assembly must sit flush or slightly below the surface of the Chassis Track Base.
If a Flat Head screw does not sit at least flush, it is recommended to leave the other screws in place and use a countersink bit on the hole to achieve a flush fitting (refer to Section 3.2 for Countersinking procedure).
4.3 Assembly of the Rear Handle Wall and Cartridge Release Lever
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