Bug Labs assembly instructions

Bug Labs - Assembly Instructions 12-3-07 Page 1 of 20
Hardware
1. Spring wire - 2. M2 X 14mm 3. M2 X 5mm 4. M2 X 3mm 5. M2 X 4mm 6. 0-80 X 7. 0-80 X .125”

1 per module flat head Allen flat head Allen Threaded button head .125” flat threaded
screw screw inserts Allen screw head Allen insert
4 per base unit 4 per base unit 10 per base unit 2 per base screw 2 per base unit
4 per module 4 per module unit 2 per base
unit
Press in inserts into the upper housing, until flush with the surface of the receiving openings. (A press or vise is needed.)
Attach the logo plate.

Press in inserts into the lower housing, until flush with the surface of the receiving openings. (A press or vise is needed.)
Press in inserts into all of the modules’ upper housings, until flush with the surface of the
receiving openings. (A press or vise is needed.)
The ON/OFF light pipe and the Hot keys’ light pipes need to be masked in the areas indicated here. They then need to be painted silver (or
white), then black. Make sure the paint is opaque enough so light cannot leak through.
Note: the ON/OFF light pipe shown here has already been masked and painted.
Place ON/OFF light pipe and insert molded tripod mount into their places shown here.
Note: The tripod mount is wider than it is tall. It will fit snugly when oriented correctly.
Fold Base LCD ribbon over on top of its connector as shown here.
Then fold the diffuser/LCD to the position shown here. Make

sure the LCD stays adhered to the diffuser.
Plug the ON/OFF slider onto the ON/OFF switch as shown here. Note: The hole is off center. The short end must face the PCB CL.
PCB CL
Don’t put the board in the upper housing yet, but when you do make sure the switch fits into its channel properly. This will require you to push
it slightly toward the PCB CL. If you don’t it could cause the switch post to break off.
Place the diffuser/LCD into its position on the upper housing. Tuck the LCD ribbon between the PCB and the upper housing.
Now place the PCB into the upper housing. Line up the locator posts in the upper housing with the holes on the PCB marked below.
Don’t forget to line up the ON/OFF switch!
Now use the 2 (M2X4mm button head) screws to fasten the PCB to the upper housing.
Place the speaker into the upper housing. Press it all the way down and route its wires behind the tripod mount like so.
Route the diffuser wires around behind the notch here. This is
where the 4way rocker switch will go.
Press the 4way rocker button onto the 4way rocker switch. Press the 4way daughter board into its notch on the upper housing.
Route the wires as seen below.

Press one of each of the 4 light pipes, all the way into its corresponding pocket on the hot key strip.
The extension off the back of the light pipes should face the connected edge of the hot key strip.
Note: The light pipes shown here have not yet been masked and painted. You must paint them before this step.
Take the light pipe shroud and place it on the PCB, over the 4 LEDs for the hot keys. You can still see each of the 4 LEDs through the 4
openings in the shroud.
Place the Hot key strip in faceplate (see below) Put the faceplate tab in its notch in the upper housing. Then pivot it in
toward the PCB. Make sure the extensions off the back of the light pipes
go into the channels in the light pipe shroud, above the LEDs.
Place the tab on the other end of the faceplate into its notch on the upper housing.
Take the Select button and slip it into its hole on the face plate. Make sure the flat edge faces up.
Plug in battery connector with the red wire closer to the PCB CL. Bend the wires so the battery stays in position like below.
Line the lower housing up directly over the upper housing assembly. Make sure the battery clears its location ribs.
Pinch the 2 housings together. Press in a little on the face plate and make sure the ribs on its top and bottom edge are received by their
channels in the upper and lower housings.
Make sure the notches for the 4way daughter board and the diffuser, line up with them.
Screw in the 4 (M2 X 14mm) Screws.
Screw in the 4 (M2 X 5mm) screws. Then the 2 (0-80 X .125”) screws.
Pinch the parting line together as you tighten down the screws so there is no gap.
(M2 X 5mm) screws
(M2 X 5mm) screws
(0-80 X .125”) screws

Take the LCD spacer and put its pegs through the corresponding holes on the PCB.
Make sure the screen

is seated properly in
its pocket. The screen
Line the LCD ribbon up with its clearance Place the spring wire should be tight against
recess on the upper housing. Then put the in position in the lower the edge of its opening.
PCB assembly in the upper housing. housing. Then place The screen could crack
the lower housing in the when screwed together Screw in the 4 (M2 X
upper housing. if not. 5mm) screws.
Take the motion sensor sleeve and snap it through the opening in the upper housing.
Line the gps port up with its opening on the upper housing. Pivot the board into the upper housing. The port should be flush with the outside
wall.
The samtek connectors always line up with the grip details on the upper housings.
The lower housings of all modules assemble the same as show on the LCD module.

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Bug Labs - Assembly Instructions 12-3-07 Page 1 of 20

1. Spring wire - 2. M2 X 14mm 3. M2 X 5mm 4. M2 X 3mm 5. M2 X 4mm 6. 0-80 X 7. 0-80 X .125”

Attach the logo plate.

Then fold the diffuser/LCD to the position shown here. Make

Route the wires as seen below.

(M2 X 5mm) screws

(M2 X 5mm) screws

(0-80 X .125”) screws

Make sure the screen

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