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Component Dimension Audit — Purchased Parts vs. As-Drawn

Purpose. After the IBC tote sizing error (assumed "600 L" small totes; the real food-grade caged product is 1,000 L / 1219×1016×1,168 mm, which forced the entire ibc-reconfig-v2 rework), this audit reconciles every major purchased-as-is component against the size used in the 3D models / 2D diagrams (tbs_constants.py). The goal: no other component is modeled at an assumed size that the real product doesn't match.

Scope. Purchased components with a fixed catalog size — fans, pumps, accumulator, filters, IBC totes, batteries, solar, evap cooler, bearings, linear guides, leadscrews, nozzles. Excluded: fasteners and standard small fittings (nuts/bolts/valves/elbows/ camlocks/unions), and fabricated-to-spec items (RHS steel, ACM panels, the Ø900 drum, the Ø89 pivot post, plywood) — those are cut to the drawing, so there is no "product ≠ drawing" risk.

Method. Real dimensions are from the manufacturer/retailer datasheet (linked). Modeled dimensions are the tbs_constants.py value(s) the generators draw. mm.

1. Findings summary

# Component Real product (datasheet) Modeled Verdict
1 IBC tote (1,000 L caged) 1219×1016×1168 IBC_W/IBC_D/IBC_H_1000 ✅ FIXED (v2)
2 LiFePO4 battery, 100Ah 12V (Renogy Smart Lithium) 330×172×214 — Renogy 12V 100Ah Smart Lithium BA_W/BA_D/BA_H ✅ FIXED
3 Shurflo 2088-554-144 pump (P-01 Blue supply) 216×127×114 — Shurflo 2088-554-144 PUMP_D×PUMP_YD_SPAN×Z ✅ FIXED (minor) — protrusion PUMP_D 100→114
4 Big Blue filter housing 4.5"×20" (separate) Ø184×594 — Pentek 4.5×20 BB BB_OD/BB_H 3-separate design of record (2026-07): combo → 3 separate housings + frame per plumbing-report §3.1/§7.2. Prices indicative — firm at the Aug-2026 re-price.
5 150×150×50mm axial fans 150×150×50 FAN_DIAM/FAN_BODY_D ✅ FIXED
6 Evaporative cooler 508×254×711 — Hessaire MC18M EVAP_W/EVAP_D/EVAP_H ✅ RESOLVED
7 SeaFlo accumulator (0.75 L) 200×127×125 — SeaFlo SFAT-075-125-01 Ø127×200 cyl ✅ FIXED — cylinder 150→200
8 304 SS RHS 40×25×3mm, 8 ft * 40×25×3 (model uses 40×25×3)

Excluded from the model but listed for BoM completeness: Solar panel (Renogy 200 W rigid ≈ 1491×699×35, varies by model — mounted externally, no container clash).

2. Detail + sources

All items below are now resolved (see the §1 summary and §4 remediation); each entry is retained as the as-found audit record — the Problem/Action text describes the discrepancy and the fix that was applied.

2. Battery — Renogy 12 V 100 Ah LiFePO4 ✅ RESOLVED (§4)

  • Real: 330 × 172 × 214 mm (L×W×H). Renogy product page · spec via Renogy spec listing
  • Modeled: BA_X=1810, BA_W=500, BA_D=120, BA_H_LO=150, BA_H_HI=650 → bank 500(X)×120(Yd)×500(Z); each of 2 packs ~240×120×500.
  • Problem: the modeled pack is 500 mm tall and only 120 mm deep; the real pack is 214 mm tall and 172 mm deep. Two packs side-by-side along X are 2×330 = 660 mm (vs modeled 500), or stacked are 428 mm tall (vs 500). The battery-bank footprint on the pinhole wall and its clearances (electrical panel above, cable runs) are all drawn against the wrong box.
  • Action: set BA_* to two real 330×172×214 packs (decide side-by-side vs stacked), re-render electrical/floorplan/assembly + the film-plane near-wall ghost, re-check EP-above-battery clearance.

3. Pump — Shurflo 2088-554-144 ✅ RESOLVED (§4)

  • Real: 8.5"L × 5"W × 4.5"H = 216 × 127 × 114 mm. Fresh Water Systems · datasheet PDF
  • Modeled: PUMP_D=100 (pump zone width). 4–5 pumps tile the Corridor Plumbing Panel.
  • Problem: a real 2088 is 216 mm long × 127 mm wide — the panel pump columns are drawn ~half-size. With 5 of them plus the accumulator + 3× 594 mm filters, the panel layout must be re-checked for fit (panel face is 270 mm corridor × 2,060 mm tall).
  • Action: set the modeled pump footprint to ~216×127×114, re-lay-out the panel (generate_panel_layout.py + 3D equipment_panel()), re-check corridor depth.

4. Filter housing — Big Blue 4.5" × 20" ✅ RESOLVED (§4)

  • Real: Pentek 20×4.5 BB = 23⅜" × 7¼" = 594 mm tall × Ø184 mm. Pentek 20" BB · allfilters 20×4.5
  • Modeled: BB_OD=184, BB_H=594 (a 4.5×20 housing — matches the real dimension above).
  • As found: BB_OD=130, BB_H=340 drew a 10" housing while the BoM specified 4.5"×20" cartridges.
  • Resolution: kept 4.5"×20" for the media life (~2× the interval between changes). The model was set to BB_OD=184 / BB_H=594; the housings hang as a horizontal bank high on the pinhole wall (heads pinned near the ceiling, sumps to ~Z1746), not a vertical stack, so the extra length costs walkway head clearance (shoulder height) rather than a tall panel run. Panel re-rendered, filter cost re-summed. Reversible to 4.5"×10" (same heads/ports) if the clearance becomes an operational issue.

5. Fan — AC Infinity Cloudline S6 ✅ RESOLVED (§4)

  • Real: 6" (152 mm) duct; unit 7.9×12.6×8.4" = 200 × 320 × 213 mm, an inline duct fan. AC Infinity S6
  • Modeled: FAN_DIAM=150 (≈ the 152 duct ✓) but FAN_BODY_D=50 — drawn as a thin axial panel fan in a 300 mm baffle duct (DUCT_DEPTH=300).
  • Problem: the S6 is 320 mm long — it won't sit flush ("fan bodies do not protrude beyond the panel face" is false for an S6) and it exceeds the 300 mm baffle-duct depth. The design intends a compact 150 mm axial panel fan; the S6 is a different form factor.
  • Action (decision needed): either (a) spec a thin 150 mm 12 V axial panel fan (matches the drawing) and drop "AC Infinity S6", or (b) keep an inline fan and redesign the baffle-duct housing to accept a ~320 mm inline body.

6. Evaporative cooler — assumed a nonexistent 12 V DC unit ✅ RESOLVED

  • Was: the model assumed a 12 V DC "Jetstream 110" ground cooler that does not exist — Portacool's real Jetstream line (models 220–270) runs on 120 V AC, not 12 V DC.
  • Market reality (researched): there is no good native-12 V DC ground-placed evap cooler. The only 12 V options are RV-roof units (TurboKool 2B-0001, ~$300 — rejected: roof penetration, roof-coupled vibration, transport conflict), a too-weak personal spot cooler (Transcool E3), or the premium Solar Chill line (native 12 V, ground, but $1,100+ and sole-source).
  • Decision: a commodity 120 V AC swamp cooler (Hessaire MC18M, ~$130) on a dedicated 12V→120V pure-sine inverter (Victron Phoenix 12/375 GFCI, ~$210). Keeps the cooler a swappable multi-vendor part; the inverter is general-purpose. Trade-off accepted: +inverter complexity and a 4-print day now needs solar (already within the published envelope).
  • Done: EVAP_* → 508×254×711 (real Hessaire MC18M, official 20×10×28 in); INVERTER_* constants added; Circuit E re-based 80 W → 97 W on the 12 V bus (85 W AC ÷ 0.88) in calculate_energy_budget.py; energy/cost/shopping/ventilation/electrical reports re-summed; stow zone re-checked (cooler X1450–1958, clear — 51mm roomier after the datasheet correction); AC isolation/GFCI/equipotential-bonding design added in Electrical §7.6.

7. Accumulator — SeaFlo 0.75 L (SFAT-075-125-01) ✅ RESOLVED (§4)

8. Spray-bar beam ✅ RESOLVED (§4 — naming)

  • BoM line says 1½"×1½"×⅛" (= 38.1×38.1×3.2 mm); the spec/model use 40×40×3 mm. Pick one — they differ by ~2 mm and the carriage saddle clamps are cut to the chosen section.

3. Catalog parts — spec'd by part number (confirm dims match the catalog)

These are ordered by an exact catalog number, so the model should already match — listed for completeness; confirm the drawn size equals the catalog dimension:

Component Catalog Expected dim Status
Linear rail HGR20 HGR20, 2,200 mm 20 mm rail width, 2200 long (RAIL_LEN) confirm
Carriage HGH20CA HGH20CA flanged standard HGH20CA block confirm
Acme leadscrew ¾"-6 McMaster 6289K36 ؾ" (19 mm) confirm
Rod-end bearing GIR25-DO / McMaster 60645K73 25 mm bore confirm
Drum bearing SKF 6215-2RS1 75×130×25 confirm
Tilt-swing bearing GE50-DO-2RS Ø50 bore confirm
Solar panel Renogy 200 W ~1491×699×35 (external) no clash
MPPT Victron 100/50 ~100×113×40 (in enclosure) no clash

4. Resolved decisions (2026-06-15) + remediation

Component Decision Real dim used Model change BoM change Status
Fan keep the drawn 150 mm axial panel fan; swap the product 150×150×50 none (model already 150×50) "AC Infinity S6" → 150×150×50 mm 12 V DC axial fan (15050-12V) ✅ done
Filter keep 4.5"×20" (media life) 594 × Ø184 BB_OD 130 → 184, BB_H 340 → 594 spec/model = 4.5×20; cost ~$336–550; cartridge intervals ~2× ✅ done
Battery resize to real pack, side-by-side 2× 330×172×214 BA_D172/BA_H_HI364/BA_W680/BA_X1540 dims added ✅ done (line-of-sight passes)
Pump resize 216×127×114 PUMP_D 100→114 (W/L already matched) dims added ✅ done
Accumulator minor 200×127×125 cyl 150→200 dims added ✅ done
Spray beam metric 40×25×3 (304 SS RHS) none alu SHS 40×40 → SS RHS 40×25 (carriage shrink, 2026-07-01) ✅ done
Evap cooler 120 V AC cooler + 12V→120V inverter (no good 12 V DC ground unit exists) 508×254×711 (Hessaire MC18M) EVAP_* 600×350×800→508×254×711; INVERTER_* added Circuit E re-based 80→97 W; AC isolation/GFCI/bonding Electrical §7.6 ✅ done

3D re-sends — done. The earlier audit batch (filter Ø + ACC + battery) was sent and overview.skp re-saved 2026-06-15; the evap-box re-dimension (Hessaire MC18M) + Circuit-E inverter box followed (overview re-saved in 1872583b, inverter leader label in 99ec629c). generate_sketchup_model.py builds the evap at EVAP_W×EVAP_D×EVAP_H + the inverter. Only the manual Sketchfab re-uploads (Alvin's step, same model IDs) may remain.

Cost re-sum CLOSED (2026-06-15): the held bundle (fan −~$70, filter, evap cooler + inverter) is now re-summed. Cooler subsystem (cooler $130 + inverter $210 + DC protection $40 + AC outlet $25) lands in cost-breakdown 5b ($769→$830 mid); the new fan ($50) is folded in; grand total $25,399→$25,460 mid; Scenario A $19,882→$19,952, Scenario B $25,322→$25,383. (The cost-breakdown's water-system filter estimate already reflected a 10″-class figure, so no separate cat-5 filter adjustment was needed; the master-shopping-list BOM filter $282–445 is authoritative.) (These totals are the 2026-06-15 remediation deltas — a dated snapshot; the current build total is generated in the Cost Breakdown.)

This document is the source of truth for the purchased-part dimensional reconciliation; update it as each component is resolved.