USB enclosures

Just got the modified USB enclosures; the boss was enlarged to create more "interference" meaning that when you push the two halves together they lock tightly.

Now either the manufacturer winged this and just used hand tools, or they did this with surgical precision and quite a bit of foresight.

The issue is, all four bosses have unequal diameters (by a small fraction of a mm, not visible with the naked eye). So they create different levels of interference. One is perfect, the other 3 are progressively too loose.

Well, if they planned this it was a smart move because this way we do not risk ruining the mold (if they make one of the bosses too thick there will be no way to fix it - you can only add material by mold modifications, not remove it, except in very easy cases). And, we get to try four diameters in no more than 2 steps.

We've sent them back the results and told them which boss is the right one and they'll make sure they all have the same circumference; this will be done with electrical discharge machining to make sure they don't overdo it and mess up the mold. In hardware, there is no Undo! :)

We still need to

- ensure the USB closes perfectly (1 week or less?)
- polish & texturize (1 week?)

And then, we're really ready to create the real plastic parts.

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