1 Preparation

Everything to have done, have on hand, and have checked before starting the C2 power-stage build.

Note
This chapter is a skeleton. The structure is complete; fill in the specific part numbers, torque values, and quantities as the build is finalized.

Prerequisites

These items must be complete before power-stage assembly begins:

• Control assembly completed and tested - the control module must be fully assembled and verified before it is needed for the later chassis-board and final-assembly chapters. See the Control Assembly assembly guide (OV-CA-AG-INDEX).
• Firmware flashed - main MCU and safety coprocessor firmware flashed and confirmed booting. See the Control Assembly software manual (OV-CA-SWM-INDEX).
• Prior build chapters complete - each chapter in this guide assumes the chapters before it are done; do not skip ahead, as later steps rely on hardware installed earlier.

Required documents

• This assembly guide (OV-C2-AG-INDEX), printed or on a shop tablet.
• C2 bill of materials - generate the current fabrication/BOM package with BOMManager and verify all parts are on hand before starting.
• Relevant design documents (OV-C2-DD-INDEX) for background on torque and thermal decisions.

Tools

• Torque wrench covering the M5/M6 range (8 N·m capability required)
• Hex key / driver set
• ESD-safe tweezers and small hand tools
• Multimeter
• Permanent marker (for torque-strip witness marks)
• Soldering station and solder (PCB chapters only)
• Clean, lint-free gloves - mandatory when handling bus bars or high-current contact surfaces

Consumables

• Thermal interface compound
• Thread-locking compound, medium strength
• Isopropyl alcohol and lint-free wipes
• ESD bags for populated PCBs

Workspace and ESD

• Clean, well-lit bench with enough room to lay out the heatspreader and all sub-assemblies.
• ESD mat and wrist strap for all PCB population chapters and for handling the control module.
• Keep the work area free of stray metal debris at all times; metal swarf or loose hardware can short high-voltage bus bars.

Safety

SAFETY
- Do not power the inverter until all assembly, torque, and inspection steps are complete.
- Review the hazard analysis (OV-SAF-HARA-CORE) before starting; it identifies the hazards each assembly control mitigates.
- Wear clean gloves whenever handling bus bars, screws, or any high-current contact surface - skin oils increase contact resistance at joints.