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Some breakthroughs with waterproofing after we posted the last entry...
1) It seems the O-rings are all ever so slightly different in size. Perhaps this is because they have to be pulled out of the mold and they get deformed when this happens. So we found the best sized O-ring out of the bag of samples and tried that. Immediately the quantity of water leaked was reduced. We need to verify with the manufacturer why there is a size discrepancy and fix it.
2) To better test the O-ring we replaced some "filled" grommets (without holes) to the real grommets so that the O-ring and screw rings would be the only parts which could leak. We're 100% sure the screw rings do not leak. Therefore we are singling out the O-ring for testing.
3) The bottom of the enclosure has screw holes that are too small, and for this reason the screw has to tap its way in rather than just sliding in effortlessly. This has the side effect that as the screw comes out of the bottom and enters the top of the enclosure, the grooves created in the top are misaligned if the halves aren't pushed together with great strength...
Here are the new enclosures. They are made in China so the finish quality is much lower than the previous ones from Korea. Notice how nicely the rubber attachment fits with the plastic part, using four small screws (black, same as the final rubber color) and how the logo emerges through the rubber (this will be more evident when the colors aren't white and white).
There are no weekends at the labs. A new receiver plastic prototype is being produced with the mean looking machines you saw earlier, which incorporates some modifications to go from 95% waterproof to 100%. The o-ring groove and screw hole sizes have been enlarged, and the main cable hole ...
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