Service flow & 7-year parts
WanderRouter Ultra — Service Flow + DIY Policy
The promise: every module is either user-replaceable (DIY with video + tool included) or send-back-swappable through a Tier-2 Ambassador. Factory 2-year warranty on every module. 7-year spare parts guarantee — including replaceable IP67 gaskets, LiFePO4 UPS pack, cellular modem M.2 cards, and outdoor-rated antennas. Replaceable seals are explicit consumables in the parts catalog (5-year service interval).
Special notes for Ultra:
- IP67 seal integrity is gated by per-unit pressure-decay test at every service. Any cover removal triggers gasket replacement + pressure-decay re-validation.
- Tier-2 Ambassador-only modules (require potting station + IP67 seal-integrity test fixture):
- M.2 B-key cellular modem swap
- Iridium 9603N daughterboard add-on / removal
- Mainboard / SoC / Wi-Fi 7 module / cellular RF FE SMT-level repair
- eUICC tier upgrade (SMT-level chip swap)
- LiFePO4 UPS pack replacement (hot-swap kit add-on is user-DIY; pack-internal replacement is Tier-2)
- PVD finish refinishing (rare; salt-spray damage at >10 years)
- Cream top deck replacement (cosmetic damage)
- User-DIY modules (no warranty impact on rest of device):
- 5-6× external N-type bulkhead antennas (RP-SMA / N-type unscrew + replacement; new gasket from parts catalog recommended)
- SIM card insertion / replacement (open chassis required first time; subsequent SIM changes via top-deck-removal + re-seal cycle is user-DIY but tedious — eSIM is preferred for digital-nomad use)
- LoRa regional band change (firmware setting; no hardware change)
- UPS hot-swap kit accessory addition (cable connection only)
- Open-STL accessories (pole/wall/vehicle mounts, antenna tilt clips, dust covers, etc.)
- Firmware updates (OTA)
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Service request categories
| Category | Cost | Handled by | Turnaround |
|---|
| **In-warranty repair / replacement** | $0 (shipping covered both ways) | Tier-2 Ambassador depot | 5-7 business days |
| **Out-of-warranty repair** | Module cost + $75 service + shipping | Tier-2 Ambassador | 5-7 business days |
| **User-paid upgrade** (cellular modem / Iridium daughterboard / 10dBi LoRa antenna / Lux engraving) | Module cost + $75 service + shipping | Tier-2 Ambassador | 5-10 business days |
| **User-paid downgrade/swap** (module swap, same chassis) | $75 service + shipping (keep removed module in parts catalog or sell-back) | Tier-2 Ambassador | 5-7 business days |
| **Cellular modem swap** (Telit ↔ Quectel ↔ next-generation 5G Adv ↔ 6G future) | Modem cost + $75 seal-re-cert service + shipping | Tier-2 Ambassador | 5-7 business days |
| **Iridium daughterboard add-on** | $295 daughterboard cost + $75 seal-re-cert + shipping (= $450 retail equivalent) | Tier-2 Ambassador | 7-10 business days |
| **Iridium daughterboard removal (post-purchase)** | -$200 credit (for refurbished daughterboard) + $75 seal-re-cert + shipping | Tier-2 Ambassador | 5-7 business days |
| **eUICC tier upgrade** (10-profile → 20-profile premium) | $25 chip cost + $75 service (SMT-level) + shipping | Tier-2 Ambassador | 7-10 business days |
| **LoRa antenna upgrade** (4dBi → 10dBi omni) | $50 antenna cost + recommended $75 seal-re-cert + shipping (or DIY if trained) | Tier-2 Ambassador OR User-DIY | DIY 30 min / Ambassador 5-7 business days |
| **5-6× external antenna replacement** (N-type unscrew + replacement) | Antenna cost ($8-32 depending on type) + $4 gasket + shipping | User self-install | same-day (parts catalog ships in 1-2 days) |
| **Replacement IP67 gasket kit** (5-year service interval recommended) | $8/kit + shipping | User self-install (or Tier-2 if combined with other service) | same-day |
| **LiFePO4 UPS pack replacement** (every 7-10 years end-of-cycle-life) | Pack cost ($120-180) + recommended $75 seal-re-cert + shipping (or careful DIY with new gasket) | Tier-2 Ambassador OR User-DIY | DIY 60 min / Ambassador 5-7 business days |
| **UPS hot-swap kit addition** (post-purchase) | $180 kit + shipping | User self-install (cable connection only) | same-day |
| **Lux Ambassador-engraved cream top deck** (post-launch v1.x option) | $80 + $75 service + shipping | Tier-2 Ambassador (laser-etcher) | 7-10 business days |
| **DIY upgrade (user-installable modules)** | Module cost + shipping only | User | same-day (parts shipped from catalog) |
| **End-of-life recycling** | $0 (WanderVerse accepts any Ultra for recycling + $25 credit toward next purchase) | WanderVerse recycling | — |
| **Physical damage (user fault)** | Repair cost + $100 service + shipping | Tier-2 Ambassador | 7-10 business days |
| **IP67 seal failure (post-impact / cover-removal-without-re-gasket)** | $75 seal-re-cert + new gasket kit ($8) + shipping | Tier-2 Ambassador (re-seal + pressure-decay validation) | 5-7 business days |
| **Total loss** (device unrepairable) | Replacement at 50% off listed v1 price + 100% trade-in value toward any WanderRouter-family product | — | — |
| **Out-of-region service** (international or remote deployment) | Region-specific cost + shipping; partner Tier-2 workshops in EU + APAC + LATAM (post-launch expansion) | Regional Tier-2 Ambassador | 7-15 business days |
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DIY policy (legal + practical)
What you can DIY without voiding warranty:
- Install or swap user-DIY modules (RAM SODIMM during initial-setup top-deck-open; M.2 NVMe; UPS hot-swap kit accessory; open-STL accessories) — no warranty impact on the rest of the device
- Replace any of the 5-6× external antennas via simple N-type unscrew (recommend new gasket from parts catalog) — no warranty impact
- Replace IP67 gaskets at 5-year service interval (or after any cover removal) — no warranty impact (requires pressure-decay re-validation; firmware-monitored via BMP390 internal sensor)
- Print and install community-designed accessories (pole/wall/vehicle mount variants, antenna mast clips, sun-shroud, Pelican-case insert, etc.) — no warranty impact
- Customize the open-STL files in CAD and print — no warranty impact
- Update firmware manually via console USB-C — no warranty impact (rotary cover must be open during console-USB use)
- Factory-reset via reset pinhole (rear panel inside rotary cover) — no warranty impact
- Configure WanderOS settings (LoRa region, identity profile, multi-WAN priority, eSIM Manager, etc.) — no warranty impact
- Insert or replace nano-SIM card during initial setup (top-deck-open required); subsequent SIM card changes also user-DIY but require careful re-gasket — eSIM is preferred for ongoing carrier changes
User-DIY modules (documented with video, tool-friendly):
- M.2 NVMe (in/out, any variant: 500GB / 1TB / 2TB)
- Note: top-deck-open required + careful re-gasket (use spare from kit; recommend new gasket from parts catalog)
- UPS hot-swap kit accessory (external connection only)
- 5-6× external antennas (N-type unscrew + replace)
- IP67 gasket replacement at 5-year interval
- All open-STL accessories
Tier-2 Ambassador-only modules (require send-back service):
- M.2 B-key cellular modem (Telit ↔ Quectel ↔ next-generation): requires antenna RF re-tune + SAR pre-scan + IP67 seal-re-cert
- Iridium 9603N daughterboard add-on / removal
- eUICC chip swap (SMT-level — 10-profile ↔ 20-profile premium)
- Mainboard / SoC / Wi-Fi 7 module / cellular RF FE SMT-level repair
- LiFePO4 UPS pack replacement (recommended Tier-2 for proper potting + seal-integrity validation; advanced DIY users can attempt with new gasket + pressure-decay test fixture access)
- LoRa antenna upgrade install (recommended Tier-2 for proper sealing of larger 10dBi omni antenna)
- Lux cream top-deck Ambassador engraving (laser-etcher operation)
- Cream top deck replacement (cosmetic damage)
- PVD finish refinishing (if salt-spray damage at >10 years)
- Hall-effect tamper sensor or BMP390 pressure sensor replacement
- Triple-input PSU OR-ing controller replacement
What voids coverage on a specific module (not the whole device):
- Physical damage to that module (drop, liquid, mains surge, etc.) — coverage on that module ends, rest of device continues covered
- User-initiated SMT-level modification (re-soldering, chip swap outside the module concept) — coverage on that chip ends, rest of device continues covered
- Unauthorized firmware modifications that bypass our security model (e.g., flashing a non-WanderVerse image that removes privacy features) — coverage on firmware-affected areas; hardware remains covered
- IP67 seal integrity failure due to user-DIY cover removal without proper re-gasket: coverage on water-damage-related issues ends; hardware coverage remains for non-water-damage failures
What voids whole-device warranty (rare, only genuine negligence):
- Removal of the Ambassador signature card (tampering-equivalent — we use it for provenance)
- Physical damage from use outside the product's intended environment (submerged beyond IP67 spec, mechanical impact beyond MIL-STD-810G shock test, sustained use above +60°C ambient)
- Unauthorized reselling as a refurbished device without our re-cert
- AC mains tampering (any modification to the internal Mean Well RPS-65-12 PSU beyond replacement of the whole certified PSU module)
- IMEI tampering (modifying or spoofing IMEI on Telit FN990Axx is a federal crime under FCC rules; we will not service such devices)
- Bypass of FCC Part 15 compliance (modifying firmware to allow LoRa TX outside FCC limits, modifying cellular TX power, etc.)
- Use of unauthorized antennas outside WanderVerse parts catalog or open-STL gallery
- Iridium SBD service resale (would force us into FCC Part 25 cert; we will not service Ultras configured for this)
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7-year parts catalog (every module buyable individually)
| Part | Approx retail | Notes |
|---|
| **Replacement IP67 gasket kit** (1× set — face + bay + bulkhead gaskets) | $8 | 5-year service interval; recommended at any cover removal |
| **Cellular external antenna** (Taoglas TG.30.8113 UV-stable jacket) | $35 | N-type, replaceable |
| **LoRa external antenna 4dBi whip** (Taoglas GW.71.5153 fiberglass) | $25 | N-type, replaceable |
| **LoRa external antenna 10dBi omni** (Taoglas GW.05.1213) | $65 | N-type, replaceable; upgrade option |
| **GNSS active antenna** (Taoglas A.156 magnetic-mount) | $20 | SMA→N-type, replaceable |
| **Wi-Fi 7 antenna** (Taoglas TG.55.8112 dual-band, outdoor variant) | $20 | N-type, replaceable; pair sold $35 |
| **Iridium whip antenna** (4-element passive) | $35 | N-type, replaceable |
| **Telit FN990Axx M.2 B-key cellular modem** | $245 | Tier-2 Ambassador install |
| **Quectel RM520N-GL M.2 B-key (alternate)** | $235 | Tier-2 Ambassador install |
| **Iridium 9603N daughterboard** | $295 | Tier-2 Ambassador install |
| **eUICC 10-profile (Standard)** | $5 | Tier-2 Ambassador SMT-level swap |
| **eUICC 20-profile (Premium)** | $25 | Tier-2 Ambassador SMT-level swap |
| **Crucial 4GB DDR4 SODIMM** | $35 | User-DIY |
| **Crucial 8GB DDR4 SODIMM** | $65 | User-DIY |
| **WD Blue SN570 1TB M.2 NVMe** | $95 | User-DIY |
| **WD Blue SN570 2TB M.2 NVMe** | $185 | User-DIY |
| **LiFePO4 UPS pack (2× 30Ah LFP prismatic)** | $135 | Recommended Tier-2; advanced DIY possible |
| **UPS hot-swap kit (2× extension packs + dock + harness)** | $180 | User-DIY accessory |
| **Replacement Bryce TriWing+Torx driver tool** | $12 | User self-purchase |
| **AC power cord (region-specific)** | $4 | User self-purchase |
| **12V vehicle harness** | $18 | User self-purchase |
| **Solar harness 24V** | $28 | User self-purchase |
| **Pole/post mount hardware** | $35 | User self-purchase / open-STL alternate |
| **Wall mount bracket** | $25 | User self-purchase / open-STL alternate |
| **Vehicle-mount kit** | $85 | User self-purchase / open-STL alternate |
| **Pelican-case insert (printable)** | $0 (open-STL) | User-printable; or pay $35 for Tier-2-printed if user lacks 3D printer |
| **Cream top deck replacement** | $145 | Tier-2 Ambassador (cream anodize + saffron pinstripe inlay matching) |
| **Weatherproof rotary cover** | $65 | Tier-2 Ambassador |
| **Specialty replacement screws + brass bushings** (Bryce M6 set × 4) | $25 | Tier-2 Ambassador issuance |
Long-term parts commitment:
- 7-year minimum after product EOL announcement
- After 7 years: community parts-catalog contributions + open-STL files + open-source firmware allow continued support
- WanderVerse end-of-life recycling program: free + $25 credit toward next purchase
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Send-back service procedure
How it works
1. Customer contacts WanderVerse support (web form, email, phone) describing issue 2. Diagnostic call — Tier-2 Ambassador team confirms whether issue requires send-back vs in-field troubleshooting 3. RMA issued — pre-paid return shipping label + service estimate 4. Customer ships chassis in original packaging (or any padded packaging) 5. Tier-2 Ambassador receives — diagnostic, repair/upgrade, IP67 re-seal, pressure-decay test, antenna RF re-tune, SAR pre-scan (if cellular modem changed), final integration test 6. Ambassador signs the service log in customer's WanderOS Service History 7. Chassis ships back with new gasket + replacement parts 8. Customer receives — opens box, removes shrink wrap (recyclable), powers on, verifies in WanderOS dashboard
What's in the return box
- Repaired/upgraded Ultra
- Updated Ambassador signature card (if Ambassador changed; original signature stays inside chassis)
- New replacement IP67 gasket kit (1× set — for next service interval)
- Service log printout
- Any decommissioned modules (returned for user reference if requested)
Service turnaround
- Standard repair / module swap: 5-7 business days
- Complex (Iridium add-on, cellular modem swap, eUICC tier upgrade): 7-10 business days
- Cosmetic / Lux engraving: 7-10 business days
- Out-of-region: 7-15 business days (regional Tier-2 expansion post-launch; initial coverage US-only)
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In-region Tier-2 Ambassador workshops
v1 launch (Q2 2028)
- East Coast: Maryland, USA
- Mid-Atlantic: Texas, USA
- West Coast: California, USA
- Mountain West: Colorado, USA (post-launch expansion)
- Midwest: Illinois, USA (post-launch expansion)
Post-launch expansion (target year 2-3)
- EU: Berlin, Germany or Amsterdam, Netherlands
- APAC: Sydney, Australia or Tokyo, Japan
- LATAM: Mexico City, Mexico
Each Tier-2 workshop investment: $25-35k (potting station + IP67 pressure-decay fixture + RF tuning fixture + cellular SAR pre-scan jig + 22-test automated production fixture).
Tier-2 certification requirements
- Tier-1 (Standard) Ambassador certification (foundational)
- 40-hour Tier-2 training program (potting + IP67 + outdoor RF + cellular cert + LoRa + Iridium configurations)
- Annual re-certification + procedures audit
- Health-and-safety training for LiFePO4 cell handling (UL 1973 cert prerequisite)
- IMEI provisioning + carrier-cert documentation training
- Iridium MSV reseller liaison training (for customer-facing airtime activation guidance)
Ambassador wages
Per Community Pool 60/30/10 split:
- 60% of retail flows to Ambassador wages (Layer 1 ops cap 65%)
- Ultra retail $1,499 → Ambassador wage allocation $899 per unit
- Tier-2 Ambassador labor: ~60-90 min per unit at $40/hr loaded = ~$40-60 per unit (~7% of retail)
- Net positive impact: each Ambassador-completed Ultra contributes meaningfully to that Ambassador's livelihood
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Service flow examples
Example 1: Cellular modem swap (5G → 5G Advanced when available)
1. Customer requests upgrade via Companion app → Service flow 2. Tier-2 Ambassador receives chassis 3. Tier-2 procedure:
- Open monobloc via Bryce driver
- Power-down + safe-shutdown WanderOS
- Disconnect old M.2 cellular modem (Telit FN990Axx → return to parts inventory or recycle)
- Install new M.2 cellular modem (Telit FN999Axx 5G Adv when available)
- Apply selective conformal coating to new modem moisture-migration regions
- Re-mount cream top deck with new gasket from kit
- Apply silicone grease to corner bolt threads + torque to 8 N·m
- Pressure-decay test at 1 psi 60s; pass
- Antenna RF tune for new cellular modem bands
- SAR pre-scan for new modem cert paperwork
- 22-test production bring-up
- Update Ambassador signature card (record service event)
4. Ship back to customer 5. Customer powers on; WanderOS detects new modem; offers eSIM re-issue if carrier IMEI-binds 6. Ambassador wage allocation: ~$60 per service event
Example 2: Iridium daughterboard add-on (post-purchase)
1. Customer requests Iridium upgrade via Companion app → Service flow → +$450 2. Tier-2 Ambassador receives chassis 3. Tier-2 procedure:
- Open monobloc
- Install Iridium 9603N + buck-boost daughterboard via JST GH connector
- Connect Iridium whip antenna to 6th N-type bulkhead (chassis-side install)
- Apply selective conformal coating to daughterboard regions
- Re-mount with new gasket
- Pressure-decay test
- Update WanderOS firmware to include Iridium SBD daemon (was disabled in factory firmware if no daughterboard installed)
- 22-test bring-up + Iridium loopback test
4. Ship back with Iridium whip antenna in box 5. Customer attaches whip antenna; configures Iridium MSV reseller account; tests SOS flow
Example 3: IP67 gasket replacement (5-year service interval)
1. Customer ships chassis (or DIY at home with parts-catalog gasket kit) 2. Tier-2 procedure (or DIY):
- Remove cream top deck
- Inspect old gasket — typically compressed permanently after 5 years
- Discard old gasket (compostable silicone)
- Install new gasket from kit
- Re-mount cream top deck + corner bolts
- Pressure-decay test (Tier-2 fixture; or DIY with portable pressure-decay tester rented from WanderVerse)
3. Ship back (Tier-2 path) or continue using (DIY path)
Example 4: LiFePO4 UPS pack replacement (every 7-10 years)
1. Customer notices BMS reports cell-degradation in WanderOS dashboard 2. Customer requests pack replacement 3. Tier-2 Ambassador (recommended) or careful DIY:
- Remove 6× M3 bolts on bottom plate UPS bay access
- Disconnect 12V/BMS connector from BMS PCB
- Remove old pack (recycle via WanderVerse end-of-life program)
- Install new pack (parts catalog, ~$135-180)
- Reconnect connectors
- Replace UPS bay gasket
- Re-bolt + re-seal
4. Ship back or continue using
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End-of-life recycling
WanderVerse accepts any Ultra at end-of-life:
1. Customer ships chassis to nearest Tier-2 workshop (free shipping label) 2. Tier-2 Ambassador disassembles chassis 3. Components recycled per material:
- Aluminum monobloc + cream top deck + heatsink → aluminum recycler
- PCB + electronic components → e-waste recycler
- LiFePO4 UPS pack → battery recycler (per UN38.3)
- Plastic / packaging → recycle / compost
4. Customer receives $25 credit toward next WanderVerse purchase 5. End-of-life event recorded in WanderVerse Service History (provenance preserved)
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Compliance + legal
Warranty terms
- 2-year factory warranty on every module
- 7-year parts catalog commitment
- Send-back service labor: 60 minutes Tier-2 Ambassador work covered for any in-warranty service
- Customer-paid services: $75 service charge + module/part cost + shipping
Service flow audit trail
- Every service event logged in WanderOS Service History (per-unit serial)
- Updated Ambassador signature card on send-back service
- Customer can request service-history report at any time
Privacy
- WanderVerse Service History contains: serial, service date, module changed, Ambassador name. NO user identity / location / network data is recorded.
- Service requests via Companion app are routed via end-to-end encrypted channel.
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Summary
Ultra service flow is the most-Tier-2-invested service program in the WanderRouter family:
- Tier-2 Ambassador-only modules (potting + IP67 + RF tune + SAR pre-scan): cellular modem, Iridium daughterboard, eUICC, LoRa antenna upgrade, Lux engraving, mainboard SMT-level repair
- User-DIY modules: external antennas, IP67 gasket replacement (5-year), UPS hot-swap kit, open-STL accessories, firmware updates
- 7-year parts catalog: every component buyable; replaceable seals as consumables
- End-of-life recycling: free + $25 credit
- Regional Tier-2 expansion: US at v1; EU + APAC + LATAM post-launch
- Community Pool flow per service event: $40-60 Ambassador wage (60% of $75-125 service charge)
- Service turnaround: 5-10 business days typical; out-of-region 7-15 days
- Replaceable seals as consumables: explicit in parts catalog at $8/kit; 5-year service interval
This is service infrastructure designed for a 15+ year outdoor product. Customers don't replace Ultras; they service them. That's the WanderVerse repair-culture commitment made operational.
Open STL files
WanderRouter Ultra — Open STL Files
Published under Creative Commons BY-SA 4.0 for accessory parts (fully open — remix, redistribute, share-alike). The IP67 monobloc enclosure body, cream anodized top deck, weatherproof rotary connector cover, engraved saffron pinstripe inlay, and PVD finish are NOT published as STL — those are manufactured outdoor-rated components, and their visual fidelity + IP67 sealing performance binds the product. STL files in this directory cover mounting hardware + accessories + replaceable consumables that complement the chassis without changing it.
The image-locked chassis (PVD charcoal-black titanium/aluminum monobloc + cream anodized top deck + engraved saffron pinstripe + tamper-resistant captive corner bolts + 5-6× N-type external antennas + weatherproof rotary cover + amber saffron LED strip + LINK indicator) is not published as STL — it's manufactured to outdoor IP67 spec, not user-printable, and its visual fidelity + sealing integrity bind the product.
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Files (to be added in Stage 8 final production)
Mounting hardware (open-STL alternates to in-box manufactured kits)
pole-mount-bracket.stl — pole/post mount for 30-100mm diameter poles. Open-STL alternate to in-box stamped-aluminum mount kit. CC BY-SA 4.0.pole-mount-bracket.step — editable solid model in STEP format. CC BY-SA 4.0.pole-mount-30mm.stl — narrower 30mm-pole-specific variant.pole-mount-50mm.stl — 50mm-pole variant.pole-mount-75mm.stl — 75mm-pole variant.pole-mount-100mm.stl — 100mm-pole variant.wall-mount-bracket.stl — drywall + masonry wall mount. Open-STL alternate to in-box.wall-mount-bracket.step — editable.vehicle-mount-bracket.stl — Yakima/Thule roof-rack adapter for van-life / overland deployments. Open-STL alternate to in-box vehicle-mount kit.vehicle-mount-front-runner.stl — Front Runner Outfitters roof-rack adapter variant.under-eave-bracket.stl — bracket for mounting Ultra under building eaves (preferred for sun + UV protection).solar-shroud-mount.stl — adapter for adding solar-shroud accessory to chassis.marine-mast-clamp.stl — marine vessel mast-clamp mount (for boat-deployed Ultra in coastal/marine deployments; works with PVD finish + IP67 + ASTM B117 salt-spray rating).bicycle-handlebar-mount.stl — for bikepacking / expedition deployments where Ultra travels on a bike (lightweight scenarios; ~3kg total weight is at-limit for handlebar).
Antenna accessories
lora-antenna-mast-clip.stl — clamp for separating LoRa antenna from main chassis on a small mast (for installations where the chassis + antenna proximity matters).cellular-antenna-mast-clip.stl — same for cellular antenna.antenna-tilt-clip-30deg.stl — tilt clip for 30° external-antenna angle (for non-standard install scenarios where vertical orientation isn't optimal).antenna-tilt-clip-45deg.stl — 45° variant.antenna-tilt-clip-60deg.stl — 60° variant.antenna-tilt-clip-horizontal.stl — fully horizontal antenna lay-down (transit + storage; not for operation).iridium-whip-clip.stl — clip for Iridium whip antenna (when daughterboard installed).gnss-mag-mount-cable-strain-relief.stl — for GNSS active mag-mount antenna cable management.wifi-antenna-tilt-mount.stl — Wi-Fi antenna side-mount tilt accessory for tilt towards client direction.
Cable management + weatherproofing accessories
cable-strain-relief-fitting.stl — for chassis cable-entry strain relief; pole-mount drip-loop assist.cable-rake-rear.stl — rear-mount cable management rake (for organizing AC cord + Ethernet + DC harness + CAN/ignition cables).weather-shroud-sun-protection.stl — UV-protective shroud for outdoor mounted Ultra (recommended in high-temp / direct-sun deployments).marine-cover.stl — additional marine/coastal weatherproof cover (for boat-deployed Ultra).pelican-1620-insert.stl — Pelican 1620 case fitment for pop-up/disaster-response deployment (works with chassis + 6 detached antennas + AC cord + tools).pelican-1640-insert.stl — Pelican 1640 case fitment.pelican-1670-insert.stl — Pelican 1670 case fitment (larger for full-kit deployments including Starlink dish + tripod).
Service / repair accessories
gasket-press-jig.stl — bench-jig for proper gasket seating during DIY IP67 re-seal.corner-bolt-recovery-tool.stl — community-printable Bryce TriWing+Torx-compatible recovery driver (for emergency service when WV-issued driver lost).pressure-decay-test-coupling.stl — adapter to connect a benchtop pressure-decay tester to the BMP390 internal-pressure access port (for advanced DIY users).cable-pull-jig.stl — for safely pulling antenna RF cables during service.
Cosmetic accessories
desk-pad-feet.stl — 4× rubber-feet caddy that slots into bottom chassis (for surfaces where vibration-damping matters; e.g., near audio equipment in van-life RV).dust-cover.stl — optional dust-cover for Ultra during long-term storage.
Reference (not for fabrication)
chassis-reference-outline.stl — chassis outline for remix compatibility checks only. NOT for fabrication; the actual chassis is manufactured at our partner facilities. Use this only to verify your accessory designs fit Ultra's external dimensions (~300×220×80mm). License: viewing only.
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Print guidelines
Pole mount brackets (`pole-mount-*.stl`)
- Material: PETG (UV-stable, weather-resistant, load-bearing for outdoor mount)
- Layer height: 0.2 mm
- Wall thickness: 5 perimeters
- Infill: 80% gyroid (load-bearing for outdoor + Ultra's 4-5kg weight + wind load)
- Supports: yes (for U-bolt undercuts + pole-curve interface)
- Print orientation: bracket-flat-down
- Print time: ~5-7 hours
- Mounting hardware: 4× included U-bolts (M8) — already in box
- For permanent outdoor mount: ASA filament preferred (better UV resistance than PETG); PLA NOT recommended (UV degrades within 1-2 years)
Wall mount bracket (`wall-mount-bracket.stl`)
- Material: PETG or ASA (load-bearing — Ultra + 6 antennas + brick weight ~5kg + wind load)
- Layer height: 0.2 mm
- Wall thickness: 5 perimeters
- Infill: 80% gyroid
- Supports: yes (for M6 hole undercuts)
- Print orientation: flat-side-down
- Print time: ~5 hours
- Mounting hardware: 4× drywall toggle bolts or tapcons for masonry (user provides)
Vehicle mount bracket (`vehicle-mount-*.stl`)
- Material: PETG or ASA (load-bearing under vehicle vibration + thermal cycling)
- Layer height: 0.2 mm
- Wall thickness: 5 perimeters
- Infill: 80% gyroid
- Supports: yes
- Print orientation: bracket-flat-down
- Print time: ~6 hours
- Mounting hardware: per Yakima / Thule / Front Runner spec (user provides)
- For high-vibration vehicles: include vibration isolators (rubber bushings) at chassis-to-rack interface (open-STL alternate to in-box rubber bushings)
Marine mast clamp (`marine-mast-clamp.stl`)
- Material: ASA preferred (better UV + salt-spray resistance than PETG); PETG acceptable for inland boats
- Layer height: 0.2 mm
- Wall thickness: 6 perimeters
- Infill: 100% (corrosive environment)
- Supports: yes
- Print orientation: clamp-curve-up
- Print time: ~8 hours
- Mounting hardware: stainless A4-grade U-bolts (M8) — user provides; ensure stainless to match chassis bond grade
- Critical: marine deployment requires stainless fasteners + grease-coated antenna threads (mineral grease, not silicone — silicone migrates over time in marine spray)
Antenna tilt clips (`antenna-tilt-clip-*.stl`)
- Material: PETG (UV-stable; flexible-but-firm)
- Layer height: 0.15 mm
- Wall thickness: 4 perimeters (outdoor exposure)
- Infill: 50% gyroid
- Supports: minimal
- Print orientation: clip-receiver-down
- Print time: ~30-45 min per clip
- Important: tilt clips are for non-broadcast scenarios only. Tilting external antennas changes antenna pattern + gain, which may technically alter SAR exposure. For sustained TX, use vertical default orientation (no clip).
LoRa / Cellular antenna mast clip (`*-antenna-mast-clip.stl`)
- Material: PETG or ASA (UV + outdoor-stable)
- Layer height: 0.2 mm
- Wall thickness: 5 perimeters
- Infill: 80% gyroid (load-bearing for antenna + wind)
- Supports: yes (for cable channel undercut)
- Print time: ~3-4 hours
- For optimal LoRa range: mount LoRa antenna 1-3m above ground (line-of-sight) — community-mesh range scales with antenna height + line-of-sight clearance.
Solar shroud (`weather-shroud-sun-protection.stl`)
- Material: ASA preferred (UV-stable, withstands +60°C+sun direct exposure)
- Layer height: 0.25 mm (faster print, mostly cosmetic)
- Wall thickness: 4 perimeters
- Infill: 30% gyroid
- Supports: yes (for shroud dome)
- Print time: ~6-8 hours
- Color: white or reflective filament strongly recommended (reduces solar heat gain on chassis cream top deck)
Pelican-case insert (`pelican-1*-insert.stl`)
- Material: PETG (impact-absorbent + reusable)
- Layer height: 0.2 mm
- Wall thickness: 4 perimeters
- Infill: 30% gyroid (cushioning)
- Supports: minimal
- Print orientation: case-bottom-down
- Print time: ~6-10 hours (Pelican 1670 is the longest)
- Includes pockets for: chassis (with 6 antennas detached) + AC cord + 12V harness + Bryce driver + T10/T8 + ESD spudger + spare gasket kit + Starlink Mini cable (if bundled)
Cable strain relief + cable rake (`cable-*.stl`)
- Material: PETG or TPU (depending on flex requirement)
- Layer height: 0.2 mm
- Wall thickness: 3 perimeters
- Infill: 30%
- Supports: minimal
- Print time: ~1-3 hours
Marine cover (`marine-cover.stl`)
- Material: ASA (mandatory for marine; PETG yellows in salt-spray/UV)
- Layer height: 0.25 mm
- Wall thickness: 5 perimeters
- Infill: 50%
- Supports: yes
- Print time: ~6-10 hours
- Mounting: snaps onto chassis via integrated clip-tabs
Bicycle handlebar mount (`bicycle-handlebar-mount.stl`)
- Material: PETG (sturdy + flexible)
- Layer height: 0.2 mm
- Wall thickness: 5 perimeters
- Infill: 60%
- Supports: yes
- Print time: ~4 hours
- Caveats: Ultra weighs ~5kg with antennas attached; this is at the upper limit of handlebar mounting; for bikepacking, recommend mounting on top of pannier rack instead. Use only on stable, solid-frame e-bikes / cargo bikes.
Service / repair accessories (`gasket-press-jig.stl`, `corner-bolt-recovery-tool.stl`, etc.)
- Material: PETG
- Layer height: 0.15 mm (precision)
- Wall thickness: 3-4 perimeters
- Infill: 50-100% (depends on tool — recovery driver needs 100%)
- Supports: yes for some
- Print time: 1-3 hours
Desk pad feet (`desk-pad-feet.stl`)
- Material: TPU (preferred — rubbery, vibration-damping) or PETG
- Layer height: 0.15 mm
- Wall thickness: 3 perimeters
- Infill: 100% (TPU) or 60% (PETG)
- Supports: none
- Print orientation: feet-down
- Print time: ~1.5 hours
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Community
Submit your remixes to the WanderVerse STL gallery (URL TBD post-launch). Popular community designs may be selected for a "Community Collection" edition — Tier-2 Ambassadors will hand-assemble a small run of each accessory and the designer gets credit + a free Ultra unit + a Lux engraved cream top deck.
Submission guidelines: 1. Original work or properly attributed remix (CC BY-SA 4.0 share-alike requirement) 2. Print-tested with photos of completed accessory installed on a real Ultra 3. Print profile + material recommendation included 4. Include LICENSE.txt in your submission with CC BY-SA 4.0 license text 5. For mounting hardware: include load test photos / videos (Ultra weighs ~5kg with antennas attached; mount must hold under wind load) 6. For outdoor accessories: specify UV resistance / weather rating (PETG = 2-3 years outdoor; ASA = 5+ years outdoor)
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License — CC BY-SA 4.0 in plain English
You can:
- Share — copy and redistribute the STL files in any medium or format
- Adapt — remix, transform, and build upon the files
- Use commercially — print, sell, distribute the printed parts (3D printer farms, Etsy resellers, community runs are all welcome)
You must:
- Attribute — give appropriate credit to WanderVerse + the original Ambassador designer (where named in the STL metadata) + provide a link to the original
- Share-alike — if you remix, transform, or build upon the material, you must distribute your contributions under the same CC BY-SA 4.0 license
You cannot:
- Add legal-tech restrictions that legally restrict others from doing anything the license permits
Full license text: https://creativecommons.org/licenses/by-sa/4.0/legalcode
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Why open-STL accessories?
Per Standard 3 (open STL) + Standard 4 (7-year parts) + repair-culture commitment:
- Ultra is consumer hardware that lives outdoors at HAVEN safehouses, expedition sites, van roofs, and rural homes for 7-15 years; mounting hardware + accessories wear out, get lost, need adaptation
- Outdoor deployment scenarios vary widely (pole / wall / vehicle / marine / Pelican-case / under-eave / bicycle / handlebar / boat-mast / RV-roof / aircraft hangar / community-event-tent); printed accessories let users adapt Ultra to their specific environment
- Users in remote regions can't always wait 5-7 days for shipping; print locally instead
- Community remixes generate ideas we wouldn't have shipped (e.g., aircraft-hangar mount — community would have made this anyway; we publish to make it easy)
- Lower e-waste: a broken pole mount shouldn't force a whole-chassis RMA
- Marine mast clamp + boat deployment: community sailing/cruising community gets Ultra-friendly mast hardware
- Bicycle / bikepacking: community bikepacking gets handlebar mount (with caveats)
- Disaster response Pelican-case insert: field deployment teams print these for grab-and-go pop-up networks
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Future files (post-launch)
- HAVEN-specific deployment hardware (concealed / low-profile mounting for HAVEN safehouse anti-detection postures)
- Ambassador-engraved Lux variants (community-printable cream top deck overlays — won't replace manufactured cream top deck, but allow user to add Ambassador-design overlays)
- Cellular antenna 4×4 MIMO retrofit (if Ultra v1.1 ships with 2× cellular antenna option, mounting hardware for 2nd cellular antenna)
- Native satellite modem cooling shroud (for Ultra v1.4 with Kuiper / 3GPP NTN modem in M.2 slot #2)
- 6G transition mounting variants (post-2030)
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What is NOT in this directory
- ❌ Chassis monobloc body STL (manufactured aluminum + PVD; not user-printable)
- ❌ Cream top deck STL (manufactured aluminum + cream anodize; not user-printable)
- ❌ Saffron pinstripe inlay STL (engraved + UV-stable epoxy fill; not 3D-printable for visual fidelity)
- ❌ Weatherproof rotary connector cover STL (manufactured + Method-A 2-tone anodize + bayonet mechanism; not 3D-printable for IP67 sealing performance)
- ❌ Lux Ambassador-engraved cream top deck STL (Ambassador-engraved per-order, intentionally unique; v1 doesn't ship Lux variant)
- ❌ Mainboard or daughterboard PCB files (proprietary IP at v1; may open in v2.x post-launch per the open-firmware roadmap)
- ❌ Internal AC PSU mechanical files (Mean Well IP)
- ❌ External antenna mechanical files (Taoglas IP)
- ❌ LiFePO4 BMS mechanical files (BMS vendor IP)
- ❌ Iridium 9603N daughterboard mechanical files (Iridium IP)
- ❌ Bryce TriWing+Torx fastener + driver mechanical files (Bryce Fastener IP; recovery-tool open-STL is a community-printable approximation, not a 1:1 replica)
- ❌ Tier-2 Ambassador potting station + IP67 fixture + RF tuning fixture mechanical files (vendor IP; published only at Tier-2 Ambassador certification level)
The chassis IS the product. Its visual fidelity + IP67 sealing performance is image-locked. Accessories that COMPLEMENT the chassis are open-STL.