KS 16X front panel doesn't close with new inner shell

[supercurio]

Hi!

I eventually reassembled my 16X after swapping the inner shell put a knobby and it's an incredible and fun off-road beast as a result.
However I'm unable to close the front panel, so I'm searching how to fix it.

It looks like the once the connector is attached on the power button & light sensor PCB, it collide with the reinforced inner shell. The inner shell is brand new, a the font panel is from 1st batch. Here's how a new one looks like.

I'm not sure how to fix it, any suggestion?

The connector which doesn't clear. I tried flipping the assembly upside down, that didn't help

The presumably reinforced area (an inner shell screw is in there) getting in the way

Not far, but not closing.

 

Edited August 4, 2022 by supercurio

[supercurio]

I see that the newer PCBs have their connector re-oriented for better clearance, as seen in a picture on this Thingiverse front cover replacement part description.

So I guess I would need to hack something or find a replacement power button / light sensor PCB. The frame itself seems identical.
The new unit has the power button at the top, light sensor at the bottom. 

Edited August 4, 2022 by supercurio

[Funky]

Can't you simply use "hot" knife and cut out some plastic, be from the "new" inner shell or from that front panel? (From inside ofc - as i would not want any "holes" seen from outside.) That would be the simplest/fastest fix.

Or you could simply buy "new" front panel, which should match/fit the new inner shell?

Did you try this? Unscrew - flip around? Seems you did that already, if i'm not mistaking.. (Flip all front panel.)  

Edited August 4, 2022 by Funky

[supercurio]

@Funky I didn't want to compromise the inner shell since it's gonna be under heavy stress on this wheel, so I quickly bodged a solution which worked perfectly 

And the wheel is back in riding order!
Not sure for how long, but yay 🎉

[Funky]

16 minutes ago, supercurio said:

@Funky I didn't want to compromise the inner shell since it's gonna be under heavy stress on this wheel, so I quickly bodged a solution which worked perfectly 

And the wheel is back in riding order!
Not sure for how long, but yay 🎉

Hey if it looks dumb, but works - it ain't dumb.   Connect in right order now.

Edited August 4, 2022 by Funky

[Tawpie]

While you'e in there, get your "GW white goober pucky everywhere" vibe going and slather everything in waterproofing. And dust proofing, you don't want to fill your headlight with dust now that you'll be playing in the dirt all the time!

[supercurio]

Good advice @Tawpie! It was done a while ago (with clear silicon). Has held up 100%