# Walter: the next physical build

The goal is five manageable service groups, not twenty loose printed pieces every time Walter needs work.

| Service group | Current printed pieces | Purpose |
|---|---|---|
| Face assembly | Front lower shell, front crown, camera carrier | Screens and camera stay together when serviced |
| Rear cover | Rear lower shell, rear crown, service blank, touch cartridge | Reach electronics, ports and touch electrode |
| Electronics rack | Upper/lower rack, two splices, expansion shelf | Prewire the computer and future boards on a removable carrier |
| Base and power bay | Base, bottom cover, power tray, radar window | Access the selected power system from below |
| Ear assemblies | Two grilles, two speaker adapters | Replace a speaker without dismantling the entire head |

These are grouping targets for assembly instructions, not a verified removal sequence. The underlying 20-piece design is still a development model.

## Highest-value next work

1. **Choose and measure power.** Battery, regulator/hub, charge connector and shutdown behavior determine the usable internal volume. A battery's headline watts do not establish Pi-compatible power.
2. **Measure actual plugs and mount details.** Plug bodies, latch travel, straight strain relief, bends and screw engagement decide whether the real parts connect. The current model has source-based outlines plus explicit unmeasured allowances.
3. **Finish the mechanical connections.** Positive locating features, retained/captive fasteners where suitable, numbered connectors, short harnesses and intentional service slack. Finish touch-cartridge/rear-blank retention and aux/camera mounts.
4. **Refine the outer surfaces around the proven internals.** Keep the smooth astronaut reference: broad continuous curves, rounded ear transitions, clean seams and concealed base fasteners. Reduce awkward protrusions and surface waviness before reducing the whole envelope. A narrow waist or smaller shell is only acceptable if the actual harness and battery still fit.
5. **Print the small coupons, then a bare rack.** Assemble actual hardware, cables and power. Only then order an unfinished full shell for closed-case thermal, audio, touch, stability and service tests.

## Component realism

The main display uses manufacturer geometry. The other modules include simplified outlines and uncertain depths/connector exits. Their inspector labels remain authoritative. Cosmetic chip detail does not count as better fit evidence. Replace approximations with supplier CAD or measured geometry revision by revision; keep source/revision/dimension confidence attached to every part.

## Why the body is still relatively large

R07 was deliberately enlarged for working space before the battery and complete wiring were selected. This site does not secretly shrink or smooth the CAD to make it look more finished. Its updated surface material is a viewing finish only. The printing geometry remains unchanged and unapproved for a full production order.