Hardware, 3" Speaker Gasket Not Flush to Enclosure

[ForrestErickson]

Describe the Failure / Bug
A clear and concise description of what the failure / bug is. Describe the problem NOT the fix.
Short Summary of the expected behavior:
The speaker gasket should seal against the enclosure.

Short Summary of the buggy behavior:
Enclosures fabricated before 20260324 have the speaker on the "Back shell" mounted on bosses which elevate the speaker. There is no contact of the speaker gasket to the enclosure

The elevation is the height of the boss.

CC: @nk25719

[ForrestErickson]

Root Cause versus Containment

From an AI: contrast and explain root cause versus containment

Root cause analysis and containment are distinct, complementary components of problem-solving and quality management, often utilized together in frameworks like the 8 Disciplines (8D) to resolve issues. Containment focuses on immediate, temporary damage control, whereas root cause focuses on long-term, permanent prevention.

Containment, Build a solid gasket

A ring of material the height of the bosses.
ID such that the speaker gasket contacts the ring
OD such that ring fits within the circle of bosses.

Here is a FreeCAD design for a solid gasket to evaluate speaker mounting tight against the enclosure:

Measurements of Bottom Shell Bosses

Boss Height 6.12 mm
Boss OD 11.4 mm

[Yhya99]

@ForrestErickson
Is there any pictures that shows the problem ?

[Yhya99]

Double checking, should we change the Boss Height to Boss OD?

Boss Height 6.12 mm
Boss OD 11.4 mm

[ForrestErickson]

Print First Solid Gasket

This solid gasket will fit into the version 1 enclosure and allow evaluation of a change to get the speaker gasket sealing to the enclosure through the solid gasket.

Gasket in place.

I printed with brim and then cut away the brim to clear the mounting bosses.

The gasket is the same height as the mounting bosses and as the mounting screws are tighten I alternate across the center to torque evenly the speaker.

[ForrestErickson]

Let's under stand the purpose of a speaker gasket

Here it he gasket, Sony 1-529-483-11

[ForrestErickson]

Here is the STL file for which Lee is on 20260328 fabricating for evaluation spacers:

SpeakerGasket3Inch-Extrude_7.7mm.zip

CC: @nk25719

[ForrestErickson]

Idea on a design change to fix root cause.

Here red indicates where material should be added at one of the bosses.