CONCEPT ONLY: NOT FOR CNC OR PRINT.
Prior shaft 12x150, 60mm switch envelope, mirrored KFL and known motor assembly retained.
8 mm plates: 140x86 envelope; central hole OD30.2 assumed, KFL holes OD7 at +/-24 (48mm pitch).
KMT catalogue A0=16, A1=5.5, A=11.5: inner extends 10.5mm and housing 6mm from flange mounting plane. Housing projection OD29 assumed; not catalog-confirmed.
Minimum nominal clearance between centre and KFL bolt holes: 24-15.1-3.5=5.4 mm; not a strength calculation.
Whole plate height adjusts via 9.5x5.5 long slot in angle leg; initial bolt is 1mm off slot centre, nominal offsets -2 to +1mm. Plate to rail has 4mm nominal gap.
Whole plate left/right adjusts via 9.5x5.5 slots on plates, crossing each slotted angle leg, about +/-2mm subject to fit.
Axial positioning via sliding T-nuts in the 2020 profile. Brackets 20x20x18x3, 9.5x5.5 slot / 5.5 round as assumed stock.
M5 head/nut envelopes include 10mm board washers; round-hole rail fasteners use low-profile 9.5mm head, no washer; T nuts, shape and actual extrusion grooves need review.
Centre hole and bearing projection are assumptions: do NOT assume bearing moves in plate opening.
Slots geometry offers horizontal +/-2mm, vertical -2..+1mm, but assembled shaft, flange and small gaps constrain safe motion. Loosen and check continuously; do not force alignment.
KFL shape, fastener head/nut access, actual motor, electrical wiring, switch shape, stator etc not validated.
Bearing locating/floating and structural strength remain unresolved.
Positive-volume intersection checks in cubic mm:
Plate0/KFLHousing0: 0.000000
Plate0/KFLInner0: 0.000000
Plate0/corner00: 0.000000
boardfast00/corner: 0.000000
boardfast00/plate: 0.000000
railfast00/corner: 0.000000
boardfast00/railfast: 0.000000
boardfast00/rail: 0.000000
railfast00/plate: 0.000000
corner00/Motor: 0.000000
boardfast00/Motor: 0.000000
railfast00/Motor: 0.000000
corner00/SwitchEnvelope: 0.000000
boardfast00/SwitchEnvelope: 0.000000
railfast00/SwitchEnvelope: 0.000000
corner00/MotorFlange: 0.000000
boardfast00/MotorFlange: 0.000000
railfast00/MotorFlange: 0.000000
corner00/WheelHub: 0.000000
boardfast00/WheelHub: 0.000000
railfast00/WheelHub: 0.000000
corner00/Wheel70: 0.000000
boardfast00/Wheel70: 0.000000
railfast00/Wheel70: 0.000000
corner00/ownRail: 0.000000
Plate0/corner01: 0.000000
boardfast01/corner: 0.000000
boardfast01/plate: 0.000000
railfast01/corner: 0.000000
boardfast01/railfast: 0.000000
boardfast01/rail: 0.000000
railfast01/plate: 0.000000
corner01/Motor: 0.000000
boardfast01/Motor: 0.000000
railfast01/Motor: 0.000000
corner01/SwitchEnvelope: 0.000000
boardfast01/SwitchEnvelope: 0.000000
railfast01/SwitchEnvelope: 0.000000
corner01/MotorFlange: 0.000000
boardfast01/MotorFlange: 0.000000
railfast01/MotorFlange: 0.000000
corner01/WheelHub: 0.000000
boardfast01/WheelHub: 0.000000
railfast01/WheelHub: 0.000000
corner01/Wheel70: 0.000000
boardfast01/Wheel70: 0.000000
railfast01/Wheel70: 0.000000
corner01/ownRail: 0.000000
Plate1/KFLHousing1: 0.000000
Plate1/KFLInner1: 0.000000
Plate1/corner10: 0.000000
boardfast10/corner: 0.000000
boardfast10/plate: 0.000000
railfast10/corner: 0.000000
boardfast10/railfast: 0.000000
boardfast10/rail: 0.000000
railfast10/plate: 0.000000
corner10/Motor: 0.000000
boardfast10/Motor: 0.000000
railfast10/Motor: 0.000000
corner10/SwitchEnvelope: 0.000000
boardfast10/SwitchEnvelope: 0.000000
railfast10/SwitchEnvelope: 0.000000
corner10/MotorFlange: 0.000000
boardfast10/MotorFlange: 0.000000
railfast10/MotorFlange: 0.000000
corner10/WheelHub: 0.000000
boardfast10/WheelHub: 0.000000
railfast10/WheelHub: 0.000000
corner10/Wheel70: 0.000000
boardfast10/Wheel70: 0.000000
railfast10/Wheel70: 0.000000
corner10/ownRail: 0.000000
Plate1/corner11: 0.000000
boardfast11/corner: 0.000000
boardfast11/plate: 0.000000
railfast11/corner: 0.000000
boardfast11/railfast: 0.000000
boardfast11/rail: 0.000000
railfast11/plate: 0.000000
corner11/Motor: 0.000000
boardfast11/Motor: 0.000000
railfast11/Motor: 0.000000
corner11/SwitchEnvelope: 0.000000
boardfast11/SwitchEnvelope: 0.000000
railfast11/SwitchEnvelope: 0.000000
corner11/MotorFlange: 0.000000
boardfast11/MotorFlange: 0.000000
railfast11/MotorFlange: 0.000000
corner11/WheelHub: 0.000000
boardfast11/WheelHub: 0.000000
railfast11/WheelHub: 0.000000
corner11/Wheel70: 0.000000
boardfast11/Wheel70: 0.000000
railfast11/Wheel70: 0.000000
corner11/ownRail: 0.000000
KFLHousing0/MotorFlange: 0.000000
KFLHousing0/CamShaft: 0.000000
KFLHousing0/SwitchEnvelope: 0.000000
KFLInner0/MotorFlange: 0.000000
KFLInner0/CamShaft: 0.000000
KFLInner0/SwitchEnvelope: 0.000000
KFLFastEnd00/MotorFlange: 0.000000
KFLFastEnd00/WheelHub: 0.000000
KFLFastEnd00/SwitchEnvelope: 0.000000
KFLFastEnd01/MotorFlange: 0.000000
KFLFastEnd01/WheelHub: 0.000000
KFLFastEnd01/SwitchEnvelope: 0.000000
KFLHousing1/WheelHub: 0.000000
KFLHousing1/CamShaft: 0.000000
KFLHousing1/SwitchEnvelope: 0.000000
KFLInner1/WheelHub: 0.000000
KFLInner1/CamShaft: 0.000000
KFLInner1/SwitchEnvelope: 0.000000
KFLFastEnd10/MotorFlange: 0.000000
KFLFastEnd10/WheelHub: 0.000000
KFLFastEnd10/SwitchEnvelope: 0.000000
KFLFastEnd11/MotorFlange: 0.000000
KFLFastEnd11/WheelHub: 0.000000
KFLFastEnd11/SwitchEnvelope: 0.000000
M5 hardware clearance over candidate vertical travel (cubic mm intersection and mm minimum separation):
BoardFast00 dy=-2.0 intersection=0.000000 distance=0.300000
BoardFast00 dy=+0.0 intersection=0.000000 distance=1.952562
BoardFast00 dy=+1.0 intersection=0.000000 distance=2.795085
BoardFast01 dy=-2.0 intersection=0.000000 distance=0.300000
BoardFast01 dy=+0.0 intersection=0.000000 distance=1.952562
BoardFast01 dy=+1.0 intersection=0.000000 distance=2.795085
BoardFast10 dy=-2.0 intersection=0.000000 distance=0.300000
BoardFast10 dy=+0.0 intersection=0.000000 distance=1.952562
BoardFast10 dy=+1.0 intersection=0.000000 distance=2.795085
BoardFast11 dy=-2.0 intersection=0.000000 distance=0.300000
BoardFast11 dy=+0.0 intersection=0.000000 distance=1.952562
BoardFast11 dy=+1.0 intersection=0.000000 distance=2.795085
Combined adjustment corners (plate dx/dy and M5s relative bracket; no mounted shaft or surrounding structure included):
corner=0 dx=-2.0 dy=-2.0 max_intersection=0.000000
corner=0 dx=-2.0 dy=+0.0 max_intersection=0.000000
corner=0 dx=-2.0 dy=+1.0 max_intersection=0.000000
corner=0 dx=+0.0 dy=-2.0 max_intersection=0.000000
corner=0 dx=+0.0 dy=+0.0 max_intersection=0.000000
corner=0 dx=+0.0 dy=+1.0 max_intersection=0.000000
corner=0 dx=+2.0 dy=-2.0 max_intersection=0.000000
corner=0 dx=+2.0 dy=+0.0 max_intersection=0.000000
corner=0 dx=+2.0 dy=+1.0 max_intersection=0.000000
corner=1 dx=-2.0 dy=-2.0 max_intersection=0.000000
corner=1 dx=-2.0 dy=+0.0 max_intersection=0.000000
corner=1 dx=-2.0 dy=+1.0 max_intersection=0.000000
corner=1 dx=+0.0 dy=-2.0 max_intersection=0.000000
corner=1 dx=+0.0 dy=+0.0 max_intersection=0.000000
corner=1 dx=+0.0 dy=+1.0 max_intersection=0.000000
corner=1 dx=+2.0 dy=-2.0 max_intersection=0.000000
corner=1 dx=+2.0 dy=+0.0 max_intersection=0.000000
corner=1 dx=+2.0 dy=+1.0 max_intersection=0.000000
corner=2 dx=-2.0 dy=-2.0 max_intersection=0.000000
corner=2 dx=-2.0 dy=+0.0 max_intersection=0.000000
corner=2 dx=-2.0 dy=+1.0 max_intersection=0.000000
corner=2 dx=+0.0 dy=-2.0 max_intersection=0.000000
corner=2 dx=+0.0 dy=+0.0 max_intersection=0.000000
corner=2 dx=+0.0 dy=+1.0 max_intersection=0.000000
corner=2 dx=+2.0 dy=-2.0 max_intersection=0.000000
corner=2 dx=+2.0 dy=+0.0 max_intersection=0.000000
corner=2 dx=+2.0 dy=+1.0 max_intersection=0.000000
corner=3 dx=-2.0 dy=-2.0 max_intersection=0.000000
corner=3 dx=-2.0 dy=+0.0 max_intersection=0.000000
corner=3 dx=-2.0 dy=+1.0 max_intersection=0.000000
corner=3 dx=+0.0 dy=-2.0 max_intersection=0.000000
corner=3 dx=+0.0 dy=+0.0 max_intersection=0.000000
corner=3 dx=+0.0 dy=+1.0 max_intersection=0.000000
corner=3 dx=+2.0 dy=-2.0 max_intersection=0.000000
corner=3 dx=+2.0 dy=+0.0 max_intersection=0.000000
corner=3 dx=+2.0 dy=+1.0 max_intersection=0.000000
Nominal simplified axial clearances (mm): rear housing/flange 0.500000; rear inner/flange 2.000000; front housing/flange 0.500000; front inner/flange 2.000000.
KFL inner axial centre distance 104.5mm, switch envelope to inner end gaps rear15.5mm front14.5mm; computed from nominal adjusted model.