docs(plans): validate external wing/nacelle proposal; federate into nav-wire and power-routing plans

REFERENCES.md

@@ -1183,7 +1183,7 @@ FEA cross-check (ANSYS Workbench, linear-elastic model, Table 11): simulated fle
 
 **Used in:** `docs/structural_analysis.md` §6.4
 
----
+**Used in:** `airframe/README.md` §5.1
 
 ## Part XI — FDA / CDRH Laser Product Regulations
 

airframe/README.md

@@ -65,7 +65,7 @@ Thrust: 4,464 g (9.84 lbf) nacelles-only; T/W ≈ 1.61 (VTOL capable).
 
 ## Printing Specifications
 
-**Material:** CF-PETG (carbon-fiber-filled polyethylene terephthalate)  
+**Material:** 20% CF-PETG (carbon-fiber-filled polyethylene terephthalate - 20% CF)  [REF-MAT-002]
 **Nozzle temperature:** 240–250°C  
 **Bed temperature:** 80–90°C  
 **Layer height:** 0.15 mm (all parts)  

docs/plans/2026-08-26-001-nacelle-esc-intake-integration-plan.md

@@ -153,7 +153,9 @@ canonical exterior and record the aerodynamic deviation as conditional for
 owner review.
 
 #### Fine tune the circular intake flange to the canonical shell.
+
 The current shape intersects the canonical curve at multiple z values, creating a wavy profile.
+Increase the convexity of the intake flange transition to ensure a smooth, monotonic intersection with the canonical shell, eliminating the wavy profile. Ensure the flange thickness remains consistent at 2.5 mm to maintain structural integrity while minimizing weight.
 
 ### U6 -- Verify ESC cable clearance for rotation through full tilt range.
 

docs/plans/2026-08-27-nacelle-wiring-plan.md

@@ -0,0 +1,102 @@
+# nacelle wiring
+
+> **Status note (2026-08-29):** the two problems below (`4 x 10AWG conductors
+> can't fit in a 7mm cableway`, `4 x off axis 10AWG conductors can't rotate
+> or bend around 145 deg of tilt`) are **confirmed real** — see
+> `docs/plans/2026-08-29-002-nacelle-esc-power-routing-plan.md` for the
+> worked verification (wire-OD/circle-packing math, harness-port/pivot
+> offset geometry). That plan also finds the specific numbers below
+> (`SPAR_OD = 16.0`, `SPAR_BORE_D = 11.0`) are **still undersized** for a
+> 4×10 AWG bundle at a realistic wire OD (need ≥13.3 mm bore at zero
+> clearance, more with real assembly margin) — re-derived there rather than
+> corrected in place here. This file is kept as the original draft/problem
+> statement; `2026-08-29-002` is the plan of record for the power-routing/
+> torque-decoupling redesign. The nav-light + Hall-encoder portions below
+> (§2.1, §2.2 "AS5600") are separately tracked, and mostly already superseded
+> by the as-built architecture, in
+> `docs/plans/2026-08-29-001-nacelle-nav-wire-hall-reconciliation-plan.md`
+> (AS5600 specifically: already datasheet-rejected as on-axis-only — see
+> that plan's validation table row 5).
+
+## Problemm
+
+### 4 x 10AWG conductors can't fit in a 7mm cableway
+
+Minimum space is 12x12mm internal diameter -> 16mm od tube
+
+### 4 x off axis 10AWG conductors can't rotate or bend around 145 deg of tilt
+
+ESC cables must route along axis of nacelle rotation to avoid binding and damage
+
+### 8mm steel rotating spar doesn't work
+
+## Proposed solution:
+
+Replace steel rotating spar with a 16mm carbon fiber tube to provide a hollow lumen for wiring.  Re-engineer airfoil to support the new tube and provide cableways for navigation lights and sensor data.
+
+Create a pivoting joint at the wingtip joint with the nacelle and a structural ring to the nacelle around the pivot, removing the skewered shaft
+
+Drive the nacelle tilt using a toothed belt and sprockets from the fuselage mounted servo motors.
+
+Create a belt path through the wing.
+
+`This landing is going to be interesting.` - Wash
+`Define interesting.` - Mal
+`Oh God, oh God, we're all going to die.` - Wash
+
+### 1. Parameter Block & Lumen Partitioning (nacelle_pod_50mm_tandem.scad)
+
+    [ ] Step 1.1: Set up the 16 mm spar and internal wire parameters:
+
+    ```OpenSCAD
+
+        SPAR_OD         = 16.0;   // [mm] fixed carbon fiber spar outer diameter
+        SPAR_BORE_D     = 11.0;   // [mm] internal lumen diameter for 4x 10 AWG power bundle
+    ```
+
+    [ ] Step 1.2: Retain and Relocate Signal Channels: Do not delete the nav light channel. Instead, adapt NAV_CHAN_* to run along the outside of the 16 mm spar (within the rotating collar or pylon fairing wall) or allocate a dedicated, isolated micro-channel separated from the 10 AWG power bundle.
+
+    [ ] Step 1.3: Update PIVOT_Z = 111.5 and mass breakdowns to reflect the 16 mm structural envelope.
+
+### 2 Signal Isolation & Auxiliary Routing
+
+    [ ] Step 2.1: Nav Light Circuit Path:
+
+        Maintain the internal channel from the outboard WS2812C recess (NAV_LIGHT_Z = 70.0) down into the rotating nacelle pylon collar.
+
+        Provide a low-profile slip-ring or flexible service loop bridge inside the wingtip garage so the 3-core signal wire can bridge the rotating nacelle interface safely without binding.
+
+    [ ] Step 2.2: Hall Effect (HE) Tilt Encoder Architecture:
+
+        Design Recommendation: Mount the HE encoder chip (e.g., an AS5600 magnetic encoder board) statically to the fixed wingtip rib/spar mount, facing a diametric magnet embedded in the rotating nacelle hub.
+
+        Wiring Benefit: Because the sensor is stationary on the fixed wing side, its wiring stays entirely within the fixed wing harness. It never enters the twisting spar lumen, eliminating wire fatigue and keeping it physically isolated from the 10 AWG power EMI.
+
+### 3: Wingtip "Garage" & Field-Maintainable Junction
+
+    [ ] Step 3.1: Model the removable wingtip access hatch module to expose the outboard end of the fixed spar, bullet connectors for the 4x 10 AWG power lines, and the static HE encoder plug.
+
+    [ ] Step 3.2: Implement the Split-Collar Pinch Clamp with M3 heat-set inserts to secure the 16 mm spar without crushing it.
+
+    [ ] Step 3.3: Ensure the wingtip garage internal volume has logical partitioning to keep the high-power ESC bullet connectors physically separated from the low-voltage signal connections (HE encoder & nav light).
+
+### 4 Mesh Export, Baking & Verification
+
+    [ ] Step 4.1: Render and export updated port and starboard STLs:
+
+    ```bash
+
+        openscad -o nacelle_port_revs.stl nacelle_pod_50mm_tandem.scad -D SWIRL_DIR=-1 -D PYLON_SIDE=-1 -D NACELLE_SIDE=-1
+
+        openscad -o nacelle_stbd_revs.stl nacelle_pod_50mm_tandem.scad -D SWIRL_DIR=1 -D PYLON_SIDE=1 -D NACELLE_SIDE=1
+    ```
+
+[ ] Step 4.2: Re-run the hull frame baking script:
+
+    ```bash
+
+        python3 tools/bake_hull_frame.py Nacelle_Port Nacelle_Stbd
+
+    ```
+
+[ ] Step 4.3: Inspect meshes in FreeCAD to confirm the 16 mm bore clearance, power lumen, isolated nav-light path, and HE encoder bracket alignment.