Legs

AGENTS.md

@@ -242,7 +242,9 @@ both via Commo.
 
 - Read this file and the matching subsystem `AGENTS.md` before starting a task; check
   `TODO.md` and recent git history for context; verify any citation you use against
-  `REFERENCES.md`.
+  `REFERENCES.md`. `docs/solutions/` holds documented solutions to past problems (bugs,
+  design patterns, workflow lessons), organized by category with YAML frontmatter
+  (`module`, `tags`, `problem_type`) — worth a search when working in an area it covers.
 - New standards citation: look it up by REF-ID first; if absent, add it to `REFERENCES.md`
   with a validated URL and exact section, then cite the REF-ID. Never guess a section number.
 - Keep `PROJECT_INDEX.md` current for active files; when a file is archived, move its entry to

TODO.md

@@ -33,6 +33,8 @@
 - [ ] Verify 4130 / 17-4 PH / 7075 allowables vs MMPDS/AMS (REF-MAT-*)
 - [ ] Add 4130 corrosion-finish spec (zinc/cad plate) to BOM/build guide
 - [ ] Verify AK7455 off-axis geometry + pinout vs datasheet (REF-SENSOR-*)
+- [ ] ASTM D3039/D695 coupon test: CF-PLATE-2MM bending allowable (thwarts
+      built at FOS 8.5/8.7 vs the conservative 300 MPa stand-in only)
 
 ### 0.10 Update and correct documentation touching every non-archived file.
 
@@ -86,9 +88,10 @@ numeric order.)*
 
 → detail: `airframe/fuselage-mid/WBS.md` §1.1.1 (3/3)
 
-- [ ] ★ CARGO-01 payload won't fit past the wing spar (BLOCKER)
-- [ ] CARGO-02 shell bores Ø12.3 for a spar the wing retired (8.3)
-- [ ] ★ CARGO-03c coupon-test CF-PETG: >=15MPa tenon, else 2nd spar
+- [ ] CARGO-03c follow-up: coupon-test CF-PETG fusion/bearing (>=15MPa unlocks
+      the `enlarged_tenon` alternative) — the default two-rod tie-rod couple
+      is BUILT and does not block on this (`airframe/fuselage-mid/WBS.md`
+      §1.1.1.2 CARGO-03c, 2026-08-24)
 - [ ] head_shell24.stl
 - [ ] cargo_sect_shell24.stl
 - [ ] Cargo gondola shell
@@ -133,13 +136,6 @@ numeric order.)*
 
 → detail: `airframe/wings-nacelles/WBS.md` §1.1.2
 
-- [ ] ★ WING-01 S1223 section self-intersects at x/c 0.742 (BLOCKER)
-- [ ] SPAR-01 spars stop at the wall; CF thwarts fore/aft of bay
-- [ ] SPAR-02 DS3225 24.5 vs 25 kgf·cm req (re-derive); RAIL-2 2.3A
-- [ ] Re-render + re-bake both wings — Rev S1b tip OML + Rev S1c Hall
-    (THICKNESS_SCALE_TIP 1.25→1.45, thickness-only section scaling); baked wing
-    STLs and docs/img/wing_rev_r1a_sections.png are stale
-
 #### 1.1.3 — Nacelles
 → detail: `airframe/wings-nacelles/WBS.md` §1.1.3
 
@@ -259,7 +255,6 @@ numeric order.)*
 - [ ] LG-13 Define wire-end retention detail at bay bosses
 - [ ] LG-02 Bay mounting integration: backing plates, flank conform…
 - [ ] Assess foot grip on concrete/asphalt
-- [ ] LG-03 CF rod channel in middle_canonical_shell24.scad rear skid…
 - [ ] LG-06 Elastic bench check: quarter-AUW fixture, 1.5 ft drop
 - [ ] LG-07 Confirm avionics enclosure shock rating
 - [ ] LG-11 Coupon-test CF-PETG

WBS.md

@@ -219,8 +219,8 @@ see docs/WBS.md §0.10.2.)*
 - [x] Access panel frames + covers (24" Rev R)
 - [x] 49 MHz (Part 15 §15.235) wire posts
 - [x] Verify head-cargo mating boss positions in slicer — SUPERSEDED,…
-- [ ] ★ CARGO-01 payload won't fit past the wing spar (BLOCKER)
-- [ ] CARGO-02 shell bores Ø12.3 for a spar the wing retired (8.3)
+- [x] ★ CARGO-01 payload won't fit past the wing spar (BLOCKER)
+- [x] CARGO-02 shell bores Ø12.3 for a spar the wing retired (8.3)
 - [x] ★ CARGO-03 wing root mortise now penetrates — CLOSED
 - [x] ★ CARGO-03b tenon/mortise on one datum — CLOSED
 - [ ] ★ CARGO-03c coupon gates tenon vs second spar (15 MPa)
@@ -293,9 +293,9 @@ see docs/WBS.md §0.10.2.)*
 - [x] EDF cableway added
 - [x] Fuselage spar-interface mismatched — station RESOLVED (Rev S1b)
   (spar DIAMETER Ø12.3 vs 8.3 still open — see §1.1.1 CARGO-02)
-- [ ] ★ WING-01 S1223 section self-intersects at x/c 0.742 (BLOCKER)
-- [ ] SPAR-01 spars stop at the wall; CF thwarts fore/aft of bay
-- [ ] SPAR-02 DS3225 24.5 vs 25 kgf·cm req (re-derive); RAIL-2 2.3A
+- [x] ★ WING-01 S1223 section self-intersects at x/c 0.742 (BLOCKER)
+- [x] SPAR-01 spars stop at the wall; CF thwarts fore/aft of bay
+- [x] SPAR-02 DS3225 torque re-derived (aero+inertia only, gravity nulled by CG pivot) -- DS3225 clears at ~7.3% margin, no part change; 6 V tilt-servo rail resized to 2.3A/servo (RAIL-2 is unrelated -- winch/Observer rail, corrected citation)
 - [x] SPAR-04 Hall tip jog crosses the spar bore — CLOSED
 
 #### 1.1.3 — Nacelles
@@ -360,7 +360,7 @@ see docs/WBS.md §0.10.2.)*
 - [ ] Assess foot grip on concrete/asphalt
 - [x] Rev R1.4 corner V-brace (landing_leg_assy.scad) is retired
 - [x] Rev R4 closed-ring wire fuse (wire_loop_fuse.scad) is retired
-- [ ] LG-03 CF rod channel in middle_canonical_shell24.scad rear skid…
+- [x] LG-03 CF rod channel in rear skid arms (superseded by LG-26)
 - [x] landing_legs_hull_r1.stl is orphaned
 - [ ] LG-06 Elastic bench check: quarter-AUW fixture, 1.5 ft drop
 - [ ] LG-07 Confirm avionics enclosure shock rating
@@ -374,6 +374,8 @@ see docs/WBS.md §0.10.2.)*
       *(closed 2026-08-09 — 4 ft adopted)*
 - [ ] LG-18 Mass-reduction pass (leg frame / bay / thigh)
 - [ ] LG-19 Styling refinement pass vs REF-CAD-002 (cosmetic)
+- [x] LG-25 Fore bay frame vs U5 tie-rod boss: 12mm proud (relieved boss)
+- [x] LG-26 Rear skid CF-rod bore misses the skid tube (fixed)
 - [ ] Render overview SVGs using FreeCAD TechDraw
 
 #### 1.1.5 — Non-Printable Component Placeholders
@@ -1087,6 +1089,23 @@ BOM tables (not checkbox tasks) — referenced, not duplicated here:
 - [x] rear_shell24_2mm_repaired.stl — 15 bodies, all wt=True
 - [x] middle_shell24_2mm_repaired.stl — 10 bodies, all wt=True
 - [x] dorsal_antenna_fin.stl — 3 bodies, all wt=True
+    - **MESH FIX 2026-08-25** (surfaced by `airframe/freecad/assembly/
+        SerenityAssembly.FCStd` failing to open cleanly — "mesh data
+        structure has some defects"): re-measured, the published file
+        actually carried 7 bodies — the 3 real ones this line recorded, plus
+        4 degenerate zero-area single-triangle fragments not caught by a
+        per-body watertight check (each fragment IS trivially "watertight"
+        alone; the whole-file `trimesh.is_watertight` was False). Two of the
+        3 real bodies also had inverted (negative-volume) winding. Fixed:
+        dropped the 4 degenerate fragments, corrected winding
+        (`trimesh.fix_normals`), unioned the 3 real bodies via `manifold3d`
+        (same primitive as the sleeve fix above) — result is 1 body, 22
+        faces (was 56 total across all 7), fully watertight, volume 2800 mm³
+        matching the largest single real body exactly (the smaller box and
+        the mast were both fully contained within its footprint — genuine
+        duplicate/leftover fragments, not distinct features; visually
+        re-verify this reads as the intended flat blade fin, not a
+        mistakenly-collapsed multi-part design, before next print).
 - [x] cargo_sect_shell24.stl — 190 bodies, all wt=True
 
 ### 6.3 — Rev S Checkpoint (2026-07-04)

airframe/FreeCAD-scripts/Makefile

@@ -48,7 +48,7 @@ AIRFRAME := $(ROOT)/..
 SCAD     := $(AIRFRAME)/openscad
 STLS     := $(AIRFRAME)/stls
 SCRIPT   := $(ROOT)/serenity_assembly.py
-OUTPUT   := $(AIRFRAME)/Serenity-Assembled.FCStd
+OUTPUT   := $(AIRFRAME)/freecad/assembly/SerenityAssembly.FCStd
 
 # ---- OpenSCAD flags -------------------------------------------
 # --hardwarnings: treat parameter warnings as errors
@@ -71,13 +71,22 @@ FUSELAGE_STLS := \
 # (bevel housing, bevel pair, Pinion A, Nozzle Drive Pinion, sector gear) is
 # DELETED and archived (airframe/archive/); replaced by the spar-crank pushrod
 # (nacelle_pushrod_crank.stl).  See docs/NOZZLE_DRIVE_TRADE.md.
+# Rev T3 (2026-08-09, airframe/wings-nacelles/WBS.md SS1.1.3.1): the nozzle
+# flaps shingled into master+seal pairs, and the combined "asm" preview
+# split into two named-endpoint renders (FLAP_PHI = PHI_CLOSED / PHI_OPEN)
+# so serenity_assembly.py can pick the one matching each nacelle's
+# configured tilt (see nozzle_iris_stl() there). The old single
+# nacelle_nozzle_iris.stl (no suffix, always PHI_CLOSED) is superseded by
+# -closed.stl and no longer built here or imported by the assembly.
 NACELLE_STLS := \
     $(STLS)/nacelles/edf_stator_sleeve.stl               \
     $(STLS)/nacelles/edf_aft_spider_sleeve.stl           \
-    $(STLS)/nacelles/nozzles/nacelle_nozzle_iris.stl     \
+    $(STLS)/nacelles/nozzles/nacelle_nozzle_iris-closed.stl \
+    $(STLS)/nacelles/nozzles/nacelle_nozzle_iris-open.stl   \
     $(STLS)/nacelles/nozzles/nacelle_nozzle_throat.stl   \
     $(STLS)/nacelles/nozzles/nacelle_nozzle_ring.stl     \
     $(STLS)/nacelles/nozzles/nacelle_nozzle_flap.stl     \
+    $(STLS)/nacelles/nozzles/nacelle_nozzle_flap_seal.stl \
     $(STLS)/nacelles/nacelle_pushrod_crank.stl
 
 # -- Wings (SCAD-sourced part-local prints; the port/stbd wing
@@ -150,10 +159,20 @@ $(STLS)/nacelles/edf_aft_spider_sleeve.stl: \
 	    -o $@
 	@echo "[stl] $@"
 
-$(STLS)/nacelles/nozzles/nacelle_nozzle_iris.stl: \
+$(STLS)/nacelles/nozzles/nacelle_nozzle_iris-closed.stl: \
         $(SCAD)/nacelles/nacelle_nozzle_iris.scad
 	@mkdir -p $(dir $@)
 	$(OPENSCAD) $(SCAD_FLAGS) \
+	    -D 'FLAP_PHI=PHI_CLOSED' \
+	    $(SCAD)/nacelles/nacelle_nozzle_iris.scad \
+	    -o $@
+	@echo "[stl] $@"
+
+$(STLS)/nacelles/nozzles/nacelle_nozzle_iris-open.stl: \
+        $(SCAD)/nacelles/nacelle_nozzle_iris.scad
+	@mkdir -p $(dir $@)
+	$(OPENSCAD) $(SCAD_FLAGS) \
+	    -D 'FLAP_PHI=PHI_OPEN' \
 	    $(SCAD)/nacelles/nacelle_nozzle_iris.scad \
 	    -o $@
 	@echo "[stl] $@"
@@ -187,6 +206,17 @@ $(STLS)/nacelles/nozzles/nacelle_nozzle_flap.stl: \
 	    -o $@
 	@echo "[stl] $@"
 
+# Rev T3 (2026-08-09) seal flap -- 4 per nozzle, lapped 0.2 mm radially
+# outboard of the 4 master flaps (PRINT-NACELLE-FLAP-MASTER/-SEAL, 4+4).
+$(STLS)/nacelles/nozzles/nacelle_nozzle_flap_seal.stl: \
+        $(SCAD)/nacelles/nacelle_nozzle_iris.scad
+	@mkdir -p $(dir $@)
+	$(OPENSCAD) $(SCAD_FLAGS) \
+	    -D 'RENDER_PART="flap_seal"' \
+	    $(SCAD)/nacelles/nacelle_nozzle_iris.scad \
+	    -o $@
+	@echo "[stl] $@"
+
 # Rev T (2026-07-18, Option B): the tilt-to-nozzle gear train (Pinion A,
 # Nozzle Drive Pinion, sector gear, bevel pair, bevel housing) is DELETED and
 # archived; the nozzle spar-crank pushrod replaces it (RENDER_PART="crank"