Battery connector fit and factory harness variants
J12 is Molex43045-0200 at pin1(4.10,66.25), rotation180°, mating toward+Y. Pin2 is(4.10,63.25); the locating peg is(4.10,70.57). The main board remains100×80mm. Header drawing SD-43045-001 note7 limits peg-to-board-edge distance to10.16mm; the actual9.43mm leaves0.73mm nominal margin. A0.20mm edge/placement allowance retains0.53mm.
Bare header height is7.37±0.25mm plus1.40±0.25mm latch projection:9.27mm maximum, plus0.20mm assembly allowance. The separate conservative mated profile is10.81+0.25+0.20=11.26mm above the board. The2-circuit housing A dimension3.86+0.35=4.21mm is expanded by0.20mm positioning allowance per side for collision auditing. The component export contains the header, mated housing envelope, bounded rear skirt and pin protrusions.
Wire-exit Y derives from pin1 +4.32+4.60−9.91+17.56:82.82mm nominal. Adding the four drawing tolerances gives±0.83mm, plus±0.20mm assembly positioning. The conservative rear plane isY83.85. The14mm individual housing length includes its insertion; adding it to the header mouth would give the wrong mated coordinate. The24.77mm view is the separate43020 wire-to-wire mating pair.
The drawings do not dimension absolute wire-exit Z or the pack wire-exitY/Z. The CAD therefore checks a bounded service family across the full possible mated wire-height region,31.525–40.935mm, rather than attributing a guessed coordinate to Molex. A tilted R4 semicircle passes around the left PCB edge. Subsequent bends use exactR4 circular fillets. The1.85mm wire maximum comes from the43030 contact insulation range; the collision service radius includes another0.20mm axis routing allowance, with conservative box cross-sections. Final pack exit position and route length are measured on the supplied parts.
Direct variant
Use the pack's existing AWG22 leads, two43030-0007 contacts and43025-0200 housing. Accept this variant only when each measured usable lead length after crimp consumption exceeds its routed centerline length by at least3mm, with the R4 bends, connector latch and strain relief accessible. The stock70±5mm specification alone is insufficient to assert that every supplied lead passes.
Factory extension variant
If either direct lead fails reach, the assembler adds35mm of AWG22 wire to that lead using a5mm qualified overlap joint: 30mm effective reach gain per lead. The stock65mm minimum then provides95mm before connector termination. For the fallback reach bound, reserve the entire14.25mm housing depth as an upper bound on lead consumed within the connector, leaving80.75mm external before the3mm strain-relief allowance. Use the same Micro-Fit housing/contacts. This is a separate factory assembly variant, not a second installed harness.
Stagger the two insulated joints in the left under-board bay: reserved sleeve envelopesØ4×16mm centered at(6.5,63,14) and(10.5,67,17). Use a qualified5mm soldered overlap joint with aTE Raychem ATUM-3/1-0-STK adhesive-lined sleeve cut16mm (accept recovered length14–16mm); both stripped conductors remain completely inside the sleeve. Maximum finished sleeveOD4mm. Immobilize each stiff section to the insulated carrier/battery padding with an adhesive textile strain-relief tab; start R4 bends beyond sleeve ends. The exactR4 routes pass through the full16mm straight sleeve sections; the exported control points and independently checked analytic lengths are in harness-envelopes.json. Dress and fixture those routes before terminating. Trim and join only in the assembler's protected-battery procedure.
The assembler must accept the splice material/process, insulation, retention and≤2mΩ resistance per joint, with pull/thermal checks in its qualified process. Root procurement includes 70mm additionalAWG22 and two joints in the source-path resistance budget. The direct path family is54.668–61.509mm. The factory-extension family is62.274–74.174mm, including the two straight splice sections. Its conservative shortest-lead margin is65+(35−5)−14.25−3−74.174=3.576mm. This includes exact arc lengths rather than polygon-chord approximations. Both variants are collision-checked separately against the board, components and manufactured parts. Supplied pack exits must fall in the acceptedY49–51,Z13.5mm region (±0.20mm route-axis allowance); that region is an assembly datum, not a dimension stated by Jauch. Receiving inspection establishes it before crimping. The CAD reports those limitations separately from collision checks. Each fallback lead contains its original65–75mm conductor plus35mm added conductor; the5mm overlap is counted once in effective reach. There are two added pieces,70mm total new conductor, two joints at≤2mΩ each, and60mm total effective reach gain.
Sources: cached Molex manufacturer drawings sources/molex-header.pdf and sources/molex-housing.pdf; original online sources and current drawing revision are also recorded in ../procurement/battery-path-primary-sources.json. The selected pack's manufacturer outline is visible on page1 of sources/jauch-250480.pdf.