[Trac #538] Internal cable length about 1cm short, along with a wire break during an ECO

[Zarro Boogs per Child]

#538: Internal cable length about 1cm short, along with a wire break during an
ECO
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 Reporter:  jg        |       Owner:  mfoster
     Type:  defect    |      Status:  new    
 Priority:  normal    |   Milestone:  BTest-2
Component:  hardware  |    Keywords:         
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 I was installing a new sample of the touch pad into a machine today for
 testing.

 I had fun taking the machine apart apart, and ascertained that the touch
 pad is attached to the keyboard assembly by gummed backing.  I guess I
 have the honor of the first "field repair" of a machine, though this is
 really an engineering change rather than repair.

 There are two cables that connect the keyboard/touch pad with the main
 hinge and main electronics assembly.  One of them has 3-4 wires (I don't
 remember the exact number), and a connector that seats in a niche made for
 it on top of the battery housing.

 In the process of reassembling the unit, I needed to reposition the cable
 a bit to try to get it back to its niche.  I was not pulling particularly
 hard, but one of the wires (the red one on the left), broke off the pin of
 the connector.

 I stripped about 1/8" of insulation to resolder it to the connector. Once
 I had resoldered the wire to the pin of the connector (having bent the
 wire around the pin for a good joint), I found that the length of the
 cable was really marginal to fit back into the niche.

 So there are two issues here:
   1) the break of the wire from the connector pin during reassembly.
   2) if the cable were even 1cm longer, the repair would have been easier,
 and not cause me to have to have the cable under stress when reinserted
 into the niche for the connector, or possibly to have to
 pull on it in hard enough to break the wire in the first place, though I
 don't think I had actually pulled all that hard.

 It took two tries to get the unit reassembled: I had missed getting the
 bottom keyboard plastic tabs properly positioned into the green edge.
 Given that I had no instructions at all at how to take a machine, I'm
 happy I was able to successfully make this ECO, and didn't find the
 operation all that difficult.

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Ticket URL: <http://dev.laptop.org/ticket/538>
One Laptop Per Child <http://laptop.org/>