re-assembling Model F

[feltel]

Recently I was lucky and got hold of an Model F XT keyboard. I ordered a replacement foam on eBay from Canada. Upon re-assembling I`m struggling much more than expected. Over the years I renovated, bolt- and screw modded different Model Ms but the F is taking me to the limits. Even if I use as much clamps as possible there is a visible gap (ca. 4-5 mm) on top around the controller where the barrel plate and the PCB plate do not come together. I dont want to use more force cause I already killed two flippers in the process. I watched several F XT related videos and it seems an not to complicated task. When the two "parts" are clamped together how to slide the PCB plate "under" the barrel plate? Both the PCB plate and the barrel plate are straight and not bent.

For the moment I put the parts to the side. *meh*

[DMA]

pull all the key caps off.
Make sure flippers move freely inside their barrels and don't protrude outside of the barrel into the area that will be occupied by PCB - it's quite easy to dislodge them and either break them or simply wedge them into the barrel so they can't move.
Then use however many clamps you need on the top and bottom ("north" and "south", whatever) of the assembly, preferably near the "claws" on the top part. top and bottom part will be somewhat shifted relatively to each other in "east-west" direction, that's normal.
Once you're happy with alignment of the "claws" with the slots on the bottom part, take the assembly, rest it on the left edge. The bottom part supposed to be higher than the top one now.
Now, take the hammer and tap the bottom part until it slides onto the top part's "claws".

OR

Just throw the foam away, it doesn't really affect anything. Yeah, the sound will be a bit more high-pitched, but otherwise everything will be the same.

[feltel]

I managed to assemble the keyboard. Unfortunately I "killed" two flippers. To bad. I organized a spare F-XT so I could snatch two flippers. I also build an XT-to-USB converter using this firmware https://www.tmk-kbd.com/tmk_keyboard/ed ... sb_32u4_xt and an Pro Micro clone. It works well, all keys register but the Spacebar does not. It does not show even using hid_listen. Bummer.

Can anyone give me hope of fixing this without taking the keyboard apart again?

[DMA]

Can anyone give me hope of fixing this without taking the keyboard apart again?

I don't think so. But if you, when assembling it, lay the top plate not on the table, but on some supports that will leave barrels hanging, and use clamps like https://www.amazon.com/dp/B097P8L5TV (get the largest available size) to hold it together while you're sliding the bottom plate in - you'll significantly reduce your chances of damaging flippers.
Good luck!

[feltel]

Just another question before I start another try in assembling an F-XT. The flipper of the spacebar goes on top of the metal bar, correct? Like on this photo?

PXL_20250410_160204101.MP.jpg (663.38 KiB) Viewed 59 times

[DMA]

I guess so - no other place to go, really. You should, however, remove all keycaps before attempting reassembly.