WanderRouter Ultra — Decision Log

Running log of every keep/swap/drop decision through Stages 0–10. Each entry cites source (image render, parts-library reuse, original spec inheritance, _VALIDATION-2026-04-24.md, _ESIM-MULTI-CARRIER.md, sibling spec reuse, Michael direction) and dates the call. No Perplexity queries this run — local refs only per task scope.

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Stage 0 — Image-spec reconciliation (2026-04-24)

Decision: the hero render is the canonical v1 chassis target. The original comprehensive WANDERROUTER-ULTRA-SPEC.md is preserved as architectural reference; the v1-image-locked design is an IP67 outdoor-rated monobloc aluminum enclosure (~300×220×80mm) with PVD charcoal-black finish + cream aluminum top deck + engraved saffron pinstripe + tamper-resistant captive corner bolts + two prominent top-mounted external antennas (LoRa + cellular) + a weatherproof rotary cover on the connector panel + an amber saffron LED strip + a "LINK" indicator. Also per Michael direction: single SKU at $1,499, not the original 7-config $1,999-$3,799 spread.

Image-locked attributes (non-negotiable v1 design constraints):

Attribute	Image-locked value
Form factor	IP67 outdoor monobloc, ~300 × 220 × 80 mm
Enclosure material	6061-T6 aluminum monobloc + titanium-PVD charcoal-black finish (marine-grade salt-spray)
Top deck material	Cream anodized 6061-T6 aluminum (Type II Class 2), full-coverage
Corner bolts	4× visible tamper-resistant captive Torx-head hex bolts (M6 stainless + brass-bushing retainers)
Saffron pinstripe	Engraved (inlay channel + UV-stable saffron epoxy) along front edge of cream top deck — NOT anodize-overlay, durable for 15+ year outdoor exposure
Top-mounted antennas	1× large black LoRa mesh antenna (~180mm fiberglass-wrapped) + 1× smaller cellular antenna (~150mm) — both upright, external, N-type bulkhead
Weatherproof connector panel cover	Cream aluminum rotary cover with saffron-anodized rim, captive bayonet 90° turn, IP67-rated when closed
Front panel indicators	Thin amber saffron LED strip (~100mm × 2mm) behind scratch-resistant polycarbonate window + round "LINK" indicator glowing saffron
Background context in image	Starlink mini dish mounted to beam/pole + Iridium whip antenna — indicates Ultra is the HUB, Starlink + Iridium are peers
Visible fans	None — passive convection via finned heatsink integrated into rear face
Aesthetic reference	Starlink × Peplink MAX HD4 × Inmarsat ruggedized
Price	$1,499 single SKU (Michael direction 2026-04-24)
SKU count	1 chassis SKU with 5 additive antenna-kit axes (not multiplying SKUs)

Source: Michael-supplied hero image render brief (2026-04-24): "Ruggedized IP67 outdoor router, roughly 300×220×80mm, PVD charcoal-black titanium/aluminum enclosure with visible tamper-resistant captive hex bolts at the corners, a cream aluminum top deck with an engraved amber saffron pinstripe, and integrated external antenna ports on one face. On top: a prominent LoRa mesh antenna (larger, black) and a dedicated cellular modem antenna. Visible weatherproof rotary cover (cream aluminum with a saffron rim) on a connector panel. In soft-focus background: a Starlink mini dish mounted to a beam/pole tilted toward the sky, plus an Iridium whip antenna. Front panel has a thin amber saffron LED strip visible through a scratch-resistant window, and a small 'LINK' indicator glowing saffron. Reference: Starlink × Peplink MAX HD4 × Inmarsat ruggedized."

Reconciliation actions taken (silent change avoided — every change documented):

1. Original "Large-Rugged IP54 chassis ~330×280×90mm (inherited Pro v2 Large)" → v1 IP67 outdoor-rated monobloc, ~300×220×80mm (smaller than Pro v2 Large, but with true outdoor rating). Drives enclosure tooling to die-cast aluminum + PVD + CNC finishing pipeline ($85-120k tooling investment). 2. Original "IP54 rating" → v1 IP67 rating (dust-tight + 1m submersion 30min). Drives Stage 7 cert budget +$8-15k + 6-10 weeks. Drives Stage 5 DFA requiring potting station + seal-integrity test fixture. Drives service flow — replaceable gaskets as consumables (Standard 4 parts catalog). 3. Original "Aluminum + silicone gasket panels" → v1 PVD charcoal-black titanium/aluminum monobloc (no separate panels; one aluminum body + one cream top deck + one rotary cover). Simplifies IP67 seal path (fewer seam interfaces) + increases tooling cost. 4. Original "Tamper-resistant fasteners not specified" → v1 4× visible tamper-resistant captive M6 Torx-head hex bolts at corners of cream top deck (Bryce Fastener TriWing + Torx-centered hybrid; field-servicable with WanderVerse-issued driver but visibly-secured-default). Supports HAVEN mobile safehouse anti-tampering posture + deters casual interference on outdoor-mounted units. 5. Original "saffron pinstripe anodize" (inherited Bridge Full Method A) → v1 engraved inlay pinstripe (CNC mill 1.5mm wide × 0.5mm deep channel into cream top deck near front edge, fill with UV-stable saffron-pigmented epoxy, cure, polish flush). Rationale: anodize pinstripe degrades under 10-15 year outdoor UV exposure; engraved inlay is permanent. Cost delta +$4/unit over anodize pinstripe. ⚠ Stage-5 inlay pigment vendor RFQ. 6. Original "LoRa module as platform but internal" → v1 LoRa antenna prominently external on top deck (per image). Platform LoRa silicon unchanged (Semtech SX1262); antenna externalized via N-type bulkhead. 7. Original "cellular antennas internal on rear" → v1 1× cellular antenna prominently external on top deck (per image — only one cellular antenna shown; 1×1 cellular vs 2×2 MIMO in Standard-5G). 1×1 MIMO accepted for v1 Ultra (outdoor + rural signal quality typically mast-advantaged; MIMO less critical than in urban dense deployments). ⚠ Stage-5 RF planning. 8. Original "Starlink external + internal antenna" → v1 Starlink external dish via dedicated WAN3 RJ45 passthrough (image shows Starlink dish in background, not on the chassis). Confirmed architecture. 9. Original "Iridium SBD as optional modem" → v1 Iridium 9603N as optional daughterboard + Iridium whip antenna external (image shows Iridium whip in background, indicating field-deployment alongside Ultra). Daughterboard installed pre-ship by Ambassador if ordered. 10. Original "UPS LiFePO4 4hr base, 8hr / 16hr upgrades" → v1 4hr LiFePO4 UPS integrated in every unit (not optional); 16-hour hot-swap is field-service accessory (external + user-attachable); 8-hour is obsoleted (4hr standard or 16hr kit). 11. Original "7 configurations at $1,999-$3,799" → v1 single SKU at $1,499 with 5 additive antenna-kit axes only. Michael direction 2026-04-24. 12. Original "28 axes configurator" → v1 5 axes (Starlink bundle / Iridium daughterboard / LoRa antenna upgrade / UPS hot-swap kit / regional LoRa band). All others are platform defaults. 13. Original "Lux Expedition cover" → v1 dropped. Single cream-top-deck aesthetic is the brand; Lux tiers muddle the visual signature. Cream top deck + engraved saffron pinstripe is the expression. 14. Original "desktop / rack / vehicle / pelican mount" → v1 outdoor pole/post/wall/vehicle mount default; desktop mount optional via open-STL feet accessory; rack-mount dropped (Ultra is not a rack device). 15. Original "front amber strip (inherited Pro v2)" → v1 thin amber saffron LED strip behind scratch-resistant polycarbonate window + small round saffron "LINK" indicator. Scratch-resistant PC window added for outdoor impact/UV resistance. "LINK" indicator engraved-labeled on cream top deck. 16. Original "RP-SMA bulkheads" (inherited Standard-5G) → v1 N-type bulkheads for outdoor/marine tolerance (RP-SMA is consumer-grade; N-type is outdoor-rated). Cost delta +$3/bulkhead × 5 = +$15/unit.

Carried forward (preserved from original spec):

Telit FN990Axx primary 5G modem (parts library reuse; already at $135 in Standard-5G + WanderCar Pro-Fleet)
Iridium 9603N SBD satellite modem optional (parts library reuse from WanderAway Expedition ~$260)
Semtech SX1262 LoRa transceiver (parts library reuse from WanderAway)
Starlink via Ethernet passthrough + local-API integration (192.168.100.1:9200) per _VALIDATION-2026-04-24.md finding 5
Multi-WAN priority engine (terrestrial → Starlink → cellular → LoRa emergency)
12V DC + 24V DC + AC triple-input PSU with MPPT solar
LiFePO4 UPS (4-hour base integrated)
Dual-mode architecture (Mode 1 / 2 / 3) per _STANDALONE-AND-PLATFORM-INTEGRATION.md
Community Pool 60/30/10 revenue split (Layer 1 ops cap 65%; Layer 2 Ambassador-voted min 35%)
Ambassador Tier-2 assembly (with potting station + IP67 seal-integrity test — not Tier-1 Standard assembly)
7-year parts commitment + replaceable IP67 seals/gaskets as consumables in parts catalog
Open STL files (CC BY-SA 4.0) for pole/post mount hardware, antenna mast clips (enclosure body + weatherproof cover NOT published — visual fidelity binds)
Carrier-agnostic SIM activation (bring-your-own-plan)
Identity-aware defaults (covert mesh mode for survivor-network use cases) per HAVEN privacy posture
GNSS always-on (u-blox M10 dedicated chip)
IMU (ICM-42688-P — for travel-mode auto-switching + vehicle integration)
CAN bus + ignition-sense (RV/vehicle integration)
SOS button (hardware, external sealed tactile)
WanderOS management plane (single pane across Standard / Standard-5G / Pro v2 / Ultra)
Meshtastic for community mesh + ChirpStack for HAVEN private backhaul (validated per _VALIDATION-2026-04-24.md finding 8)

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Stage 1 — Intake + freeze (2026-04-24)

Decision: Native SOP v2.4 design (image-locked + price-simplified run from original Ultra spec). Device ID WV-NET-ROUTER-ULTRA, revision v1.0-image-locked.

Chassis: IP67 outdoor monobloc, 300 × 220 × 80 mm, PVD charcoal-black aluminum + cream anodized top deck.
Ship target: Q2 2028 (long cert cycle: IP67 + 4-carrier PTCRB + MIL-STD-810 + LiFePO4 UL + potential FCC Part 25 legal review = ~15-18 months from EVT to ship).
SKU strategy: 1 chassis, 1 SKU code, 5 additive antenna-kit axes.
Validation references: rural off-grid Starlink household + HAVEN mobile safehouse + expedition/scientific field deployment + LGBTQ+ disaster-response pop-up network + van-life full-time overland.
Target price: $1,499 single SKU (Michael direction).

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Stage 2 — Component selection (2026-04-24)

Full BOM at BOM-normalized.csv. Key architectural decisions follow.

Wi-Fi 7 SoC: MediaTek MT7988A (preferred — UNIFIED with Router Standard + Standard-5G + Pro v2)

Why: same SoC as Router Standard family. Shared BSP across the Wi-Fi 7 router family. ~$18 vol-1k. OpenWrt mainline. 2× PCIe 3.0 x1 lanes available + USB 3.0.
Considered + rejected:
Qualcomm IPQ9574 — flagship Wi-Fi 7 SoC, more performance headroom, but closed-driver concerns, higher BOM (~$32), and breaks platform unification. Rejected.
Pro v2 SoM-class compute (Intel Atom / AMD Ryzen Embedded) — higher performance but breaks budget + BSP unification. Pro v2 uses SoM; Ultra consolidates to MT7988A to hit $1,499 price point. Pro v2 features (BGP / NetFlow / 10GbE) not required in outdoor-mobile use case.
Source: Standard spec Stage 2 decision; parts library parts.db.

Wi-Fi 7 radios: 2× MediaTek MT7996AX dual-radio (UNIFIED with Standard + Standard-5G)

Client radio: MT7996AX tri-band module ~$38 vol-1k.
Backhaul radio: MT7996AX tri-band module ~$38 vol-1k.
MLO posture: ✅-optional per _VALIDATION-2026-04-24.md finding 2. Fall-back to single-link Wi-Fi 7.
Antennas: internal RF coupling via N-type bulkheads to external antennas (not separate Wi-Fi antennas on top deck — Ultra uses cellular + LoRa external; Wi-Fi is internal-PCB + emits via integrated-IPEX-to-N-type cable to 2 side-mounted N-type bulkheads for Wi-Fi in outdoor-deployed config). ⚠ Stage-5 antenna routing — Wi-Fi antennas are side-face bulkheads, not top-mounted per image binding.

Cellular modem: Telit FN990Axx M.2 B-key (PRIMARY) — parts library reuse

Why: parts library reuse from Standard-5G + WanderCar Pro-Fleet + original Ultra spec. Perplexity-validated 2026-04-24: strongest US 4-carrier explicit cert (AT&T + FirstNet + T-Mobile + Verizon).
M.2 B-key form factor: user-replaceable card via Tier-2 Ambassador seal-re-cert service (not field-DIY; requires potting re-cure + pressure-decay test).
Cost: ~$135 vol-1k (matches Standard-5G + WanderCar).
Source: parts.db, ../router_standard_5g/DECISIONS.md Stage 2.

Iridium SBD modem: Iridium 9603N (OPTIONAL DAUGHTERBOARD) — parts library reuse

Why: parts library reuse from WanderAway Expedition spec. FCC-certified end-user terminal (no additional FCC Part 25 licensing required if customer brings own Iridium airtime). Short Burst Data only — emergency-grade messaging when everything else is down.
Form factor: surface-mount module daughterboard, installed pre-ship by Tier-2 Ambassador if ordered.
Cost: ~$260 vol-1k (from WanderAway Expedition spec). +$450 retail delta.
Airtime posture: customer brings own Iridium plan via authorized reseller. We do NOT resell airtime → we avoid FCC Part 25 licensing. ⚠ regulatory attorney review confirmed required before launch marketing (consistent with _VALIDATION-2026-04-24.md finding 4 on DA-26-278 legal review).
External antenna: included 4-element whip (visible in image background).

LoRa transceiver: Semtech SX1262 (PLATFORM) — parts library reuse

Why: parts library reuse from WanderAway (LITE / TRAIL / EXPEDITION tiers all use SX1262). Mature mainline-supported transceiver. 915 MHz US + 868 MHz EU + 920-925 MHz APAC regional configurable via firmware.
Integration: SPI to MT7988A. Daemon layer: Meshtastic (community mesh) + ChirpStack (HAVEN private backhaul) per _VALIDATION-2026-04-24.md finding 8.
External antenna: stock 4dBi 915/868 whip (Taoglas GW.71.5153 — reused from WanderAway) mounted to N-type bulkhead on top deck. Optional 10dBi omni upgrade (+$50 retail) extends community-mesh range to 15km+ line-of-sight.
Cost: ~$2.80 vol-1k silicon + ~$5.20 whip antenna (stock) + ~$28 for 10dBi omni upgrade.

GNSS: u-blox M10 (PLATFORM, dedicated)

Why: dedicated chip (separate from Telit FN990Axx's embedded GNSS) per original Ultra spec — GNSS availability is critical for vehicle-mode + HAVEN safe-zone policy; redundancy hardens availability when cellular modem is in low-power/SBD-only mode.
Cost: ~$14 vol-1k. External active antenna magnetic-mount (included, side bulkhead).

IMU: ICM-42688-P (PLATFORM) — parts library reuse

Why: parts library reuse from WanderAway Expedition. 6-axis motion + vibration. Supports travel-mode auto-switching, vehicle-movement detection, tamper/shock alarm.
Cost: ~$3.20 vol-1k.

CAN bus transceiver: MCP2518FD + TJA1463 (PLATFORM) — per `_HARDWARE-TOOLCHAIN.md` automotive reference

Why: standard automotive CAN transceiver pairing. External Deutsch DT04-3P waterproof connector for RV/vehicle integration.
Cost: ~$8 (inclusive of connector + protection).

Ignition-sense: PC817 opto-isolator + protection

Cost: ~$1.50. External Deutsch DT04-2P.

SOS button: sealed tactile + RGB LED indicator

Part: NKK YB-series sealed tactile (IP67-rated) + integrated RGB LED for armed/confirming/confirmed states.
Cost: ~$4. Flush with enclosure face; requires 2-second press to prevent false trigger.

Triple-input PSU + MPPT solar

12V DC input: Schurter 6130-series IP67 panel-mount barrel + Littelfuse SMBJ26CA TVS + reverse-polarity MOSFET (Infineon IPC180N08 N-channel with protection controller). Cost ~$14.
24V DC input: same topology, 36V TVS. Cost ~$14.
AC input: recessed IEC C14 (sealed when rotary cover closed) + 100-240V universal input PSU module (Mean Well RPS-65-12 medical-grade, 65W 12V output, IEC 60601 + UL 62368 + outdoor-rated). Cost ~$38.
Source-selector OR-ing: TPS2121 redundant supply controller ×3 cascade (AC / 12V / 24V). Cost ~$12 total. Stage-5 Flux.ai simulation for <20ms switchover dynamics (Starlink terminal drop-tolerance).
MPPT solar controller: TI BQ24640 (same as original spec). Cost ~$18. 12-36V input range; charges LiFePO4 UPS directly when solar-primary.

LiFePO4 UPS (4-hour, integrated platform)

Cells: 4× 18650-size LiFePO4 (Samsung/Molicel equivalents) + BMS PCB. Cost ~$65 assembly (matches original spec).
Thermal management: dedicated thermistor + active cooling (passive via finned rear heatsink — UPS bay is on rear face, adjacent to heatsink for thermal rejection).
User-replaceable: 6-bolt access through bottom plate (requires T10 Torx + T8 driver + re-seal gasket from parts catalog).
Cert: UL 1973 (pack safety) + UN38.3 (shipping) + IEC 62133 (cell/battery) — $15-25k cert budget per _VALIDATION-2026-04-24.md finding 7.

Connectors (all outdoor-rated):

RJ45 (×4 — WAN3 Starlink + WAN2 wired + 2× LAN): Amphenol RJMG2034334 IP67-rated shielded (sealed when rotary cover closed). Cost ~$6/each.
USB-C console: Amphenol 12401610E2 + IP67 gasket + rotary-cover protection. Cost ~$1.20.
N-type bulkheads (×5 — cellular + LoRa + GNSS + Wi-Fi×2 side-mounted): Amphenol 172101-series N-type female outdoor-rated. Cost ~$4.50/each.
DC barrel jack 12V/24V: Schurter 6130-series IP67 panel-mount. Cost ~$2.20.
CAN Deutsch DT04-3P: Deutsch DT04-3P-E004 waterproof. Cost ~$3.50.
Ignition Deutsch DT04-2P: Deutsch DT04-2P-E004. Cost ~$2.80.
AC inlet IEC C14: recessed + sealed when rotary cover closed. Cost ~$2.50.
Reset pinhole: recessed, sealed with small rubber plug (tool-required; plug retained with tether inside enclosure). Cost ~$0.30.

Enclosure manufacturing path

Monobloc aluminum body: die-cast 6061-T6 aluminum (primary tooling ~$85k) + CNC finishing (~$8/unit at vol-1k) + titanium-PVD coating (vendor: IHI Hauzer or Vapor Technologies; ~$35/unit at vol-1k).
Cream top deck: CNC-machined 6061-T6 + Type II Class 2 cream anodize. ~$35/unit.
Engraved saffron pinstripe: CNC-milled channel 1.5mm × 0.5mm + UV-stable saffron-pigmented epoxy fill (vendor: Marabu or Techspray UV-resist pigments). ~$8/unit inclusive of fill + polish.
Weatherproof rotary cover: CNC-machined 6061-T6 + cream anodize + saffron-anodized rim (bi-color anodize, Method A inherited from Bridge Full RFQ). Captive bayonet mechanism. ~$18/unit.
Rear finned heatsink: extruded 6061-T6 bonded to monobloc body + PVD-finished together. ~$12/unit.
Internal aluminum heatspreader: 6061-T6 sheet ~200×150×3mm for MT7988A + Wi-Fi radios + Telit + LoRa thermal coupling. ~$6/unit.

Potting + IP67 seal

PCB-level potting: selective conformal coating (Electrolube SCC3 urethane) on mainboard + daughterboard areas exposed to moisture migration. Ambassador Tier-2 potting station.
Seam gaskets: silicone Shore 50A O-rings + face gaskets for rotary cover, top deck join, UPS bay, all connector bulkheads. All gaskets in parts catalog as consumables (replace every 5 years or after any cover removal).
Pressure-decay test: each assembled unit pressure-decay tested (1 psi holding for 60 seconds; IEC 60529 IP67 compliance equivalent at bench-QC level); formal IP67 cert is lab-accredited per-design-revision, not per-unit.

Saffron LED indicator + "LINK" indicator

LED strip: 16× Cree CLM3C-AKA amber 0603 LEDs behind opal-acrylic light-pipe (Bivar custom 100×2mm) behind UV-stable scratch-resistant polycarbonate window (Bayer Makrolon AR 2mm). Driven by MT7988A GPIO + DMN2215U MOSFET array, PWM-modulated. Total ~$3.50.
"LINK" indicator: 1× Cree CLM3C-AKA + Bivar LP4-100 4mm round light-pipe + PC window + DMN2215U. Engraved "LINK" label via CO2 laser-etch into cream top deck. Total ~$0.85.
Color spec: ~592nm wavelength, color-matched to saffron pinstripe epoxy (same colorimeter spec as Bridge Full + Standard-5G ⚠ Stage-5 LED part matching).

Mainboard PCB

8-layer ENIG, ~240×180mm. Slightly larger than Standard-5G's 240×170mm due to triple-input PSU + LoRa daughterboard + CAN + ignition + IMU + GNSS + additional N-type + Iridium socket real estate.
Prototype: JLCPCB 8-layer; mid-run: Sierra Circuits.
Cost: ~$22/unit at vol-1k.

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Stage 3 — Compatibility review (2026-04-24)

~75-part BOM (full list BOM-normalized.csv) verified electrically + mechanically coherent. Full output: COMPATIBILITY.md.

Resolved:

MT7988A ↔ MT7996AX × 2 via PCIe 3.0 x1 each (inherited Standard/Standard-5G)
MT7988A ↔ Telit FN990Axx via PCIe 3.0 x1 (third PCIe lane)
MT7988A ↔ Semtech SX1262 via SPI (dedicated bus, standard WanderAway integration)
MT7988A ↔ u-blox M10 via UART (standard GNSS integration)
MT7988A ↔ ICM-42688-P via SPI (shared bus with SX1262 if bandwidth permits; else 2nd SPI)
MT7988A ↔ MCP2518FD CAN transceiver via SPI
Iridium 9603N daughterboard ↔ mainboard via JST GH-series waterproof connector (optional install)
5× N-type bulkheads ↔ cream top deck + side face: 1 cellular top + 1 LoRa top + 1 GNSS side + 2 Wi-Fi side
Triple-input PSU OR-ing: TPS2121 cascade verified for <20ms switchover; meets Starlink terminal drop-tolerance
LiFePO4 UPS thermal: pack adjacent to rear finned heatsink; delta-T ≤15°C under sustained load per Stage-6 model
Rotary connector cover: captive bayonet mechanism clears all underlying I/O with 1mm working clearance
Engraved pinstripe thermal expansion: CTE mismatch between 6061 aluminum (23 ppm/°C) and UV epoxy fill (~60 ppm/°C) — over -40°C to +60°C range, max differential expansion ~60 µm across 200mm pinstripe length; acceptable per outdoor vendor standard practice

Deferred / open:

🟡 PVD vendor capability for 6061-T6 aluminum monobloc at 1k volume (IHI Hauzer / Vapor Technologies / PVT Coatings) ⚠ Stage-4 RFQ
🟡 Engraved inlay pinstripe UV-epoxy pigment vendor ⚠ Stage-5 RFQ
🔴 IP67 seal-integrity test fixture per Ambassador workshop (~$25-35k each) — limits Tier-2-certified Ambassador workshops to 3-5 nationwide at v1
🔴 FCC Part 25 legal review for Iridium SBD bundled — regulatory attorney (~$5-15k) — gates launch marketing
🔴 4-carrier PTCRB cert in parallel (inherits Standard-5G posture + outdoor-specific delta) — $30-50k incremental over Standard-5G cert
🟡 Telit FN990Axx 2028 distributor lifecycle — aggregated-volume pricing ⚠ Stage-4 Telit FAE RFQ
🟡 Iridium 9603N 2028 distributor lifecycle — ⚠ Stage-4 Iridium FAE RFQ
🟡 MIL-STD-810G test lab scheduling (Intertek/Element/NTS) — 12-16 week lead
🟡 UL 1973 LiFePO4 cert inherits Bridge Full + Standard-5G HAVEN posture
🔴 Production origin (US CM vs Taiwan CM) — gates EVT; US CM strongly preferred per DA-26-278

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Stage 4 — Sourcing (Perplexity-deferred)

Same posture as Standard-5G: training-knowledge architectural review; Stage-4 Perplexity RFQ verification queued for next session.

⚠ needs validation flagged on:

Telit FN990Axx aggregated-volume pricing across Router family + WanderCar (5k+ units)
Iridium 9603N aggregated-volume pricing across Router Ultra + WanderAway Expedition
Semtech SX1262 aggregated-volume pricing across Router Ultra + WanderAway family
Titanium-PVD vendor RFQ (IHI Hauzer vs Vapor Technologies vs PVT Coatings) + lead time
Engraved pinstripe UV-epoxy pigment vendor (Marabu / Techspray / specialty)
Amphenol RJMG2034334 IP67 shielded RJ45 at vol-1k
Amphenol 172101-series N-type bulkhead at vol-1k
Schurter 6130-series IP67 panel-mount barrel
Deutsch DT04 connector family at vol-1k
Mean Well RPS-65-12 medical/outdoor-rated AC PSU
UL 1973 cell-grade LiFePO4 RFQ (parallel with Bridge Full + Standard-5G HAVEN)
Ambassador Tier-2 potting station vendor (Nordson / Techcon benchtop selective coating + dispense)
IP67 seal-integrity test fixture (pressure-decay benchtop tester; InterTech / Cincinnati Test Systems)

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Stage 5 — DFM/DFA/DFT (2026-04-24)

Full output: DFM-DFA-DFT.md.

Key decisions:

Mainboard: 8-layer ENIG, 240×180mm. Prototype via JLCPCB; mid-run via Sierra Circuits.
24-step Ambassador Tier-2 station workflow, 60-90 min/unit (vs Standard-5G's 18-25 min/unit — step-count + potting + pressure-decay drives duration).
DFT: 22 test points, 20-test automated fixture (RF chamber for cellular + Wi-Fi 7 + GNSS + LoRa + Iridium if installed), 360s/unit (vs Standard-5G's 240s).
First-run target: 100 units, ~$680 FOB platform, $1,499 retail = 55% gross margin.
Potting station + IP67 seal-integrity fixture: Tier-2 Ambassador workshop investment $25-35k per site.
Cellular antenna tuning fixture + LoRa antenna tuning fixture: shared with Standard-5G-family workshop.

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Stage 6 — Thermal/EMC/ESD + outdoor environmental (2026-04-24)

Full output: THERMAL-EMC.md.

Key decisions:

Fanless mandatory (image-binding + IP67 requirement — no vent = no fan possible without breaking seal).
Rear finned heatsink integrated into monobloc body + internal aluminum heatspreader dual-surface thermal rejection.
Idle (4G-only primary + Wi-Fi 7 dual-radio low-load, 25°C ambient) ~22W chassis-internal → comfortable.
Nominal (Starlink + 5G active + LoRa daemon + Wi-Fi 7 load, 25°C ambient) ~55W chassis-internal → at envelope; advisory at ≥40°C ambient.
Peak (all 4 WAN active + Iridium TX + UPS charging + solar input + Wi-Fi 7 full load, 25°C ambient) ~85W chassis-internal worst-case → advisory at 25-30°C ambient only; throttling above.
Outdoor environmental: operate -40°C to +60°C. Solar load at +60°C ambient + direct-sun + enclosure heat rise ~20°C = +80°C surface worst-case. Component selection reflects +105°C max junction for silicon.
Vibration: MIL-STD-810G Method 514 Procedure I (transport) + Procedure II (vehicle mount).
Shock: MIL-STD-810G Method 516 Procedure IV (transit drop 1.2m).
Salt spray: ASTM B117 for marine/coastal deployment (PVD finish withstand standard).
EMC: 4-radio coexistence (Wi-Fi 7 + 5G + LoRa + Iridium-if-installed) + CAN bus filter + GNSS isolation.
ESD: Level 4 on all external I/O (outdoor-rated).
FCC Part 15 Class A (outdoor/industrial acceptable; no residential-only restriction since Ultra is commercial/outdoor-positioned).

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Stage 7 — Compliance (2026-04-24)

Full output: COMPLIANCE.md.

Headline cert budget: ~$200-280k total launch cert.

Breakdown:

FCC Part 15 B Class A (outdoor) ~$5k
FCC Part 15 E Wi-Fi 7 host ~$10-12k
FCC Part 15 C (LoRa SX1262 + Heltec passthrough declarations + BLE if present) ~$0-500
FCC Part 22/24/27 cellular host ~$12k
FCC Part 25 (Satellite Communications) — if bundled Iridium airtime resold ~$30-50k + ongoing compliance — AVOIDED by bring-your-own airtime posture; legal review $5-15k
FCC OET 65 SAR (host, cellular + LoRa) ~$10-12k
PTCRB AT&T + T-Mobile + Verizon (3 carriers at launch) ~$75-90k
PTCRB US Cellular + FirstNet (post-launch) ~$20-30k
CE RED + EMCD + LVD ~$8-12k
UKCA ~$2-3k
ISED Canada + RSS-102 SAR ~$4-6k
UL 62368-1 ~$13-18k
UL 1973 (LiFePO4 UPS pack) ~$13-18k
UN38.3 (Li-ion shipping) ~$2-3k
IEC 62133 (cell/battery) ~$8-12k
IP67 cert (IEC 60529) ~$8-15k
MIL-STD-810G (outdoor environmental: vibration + shock + temp + humidity + salt spray) ~$25-40k
RoHS / REACH / WEEE / Prop 65 — declarations ~$500
Energy Star — N/A (Ultra is outdoor/industrial; Energy Star not applicable to outdoor deployments)
Matter 1.3+ certification ~$5-8k (Matter controller role)

Total v1 launch: ~$200-280k. Amortized over $1,499 retail × projected 1,000-unit first-year volume = ~$200-280/unit cert amortization; absorbable into 55% gross margin.

Production origin: US CM strongly preferred (DA-26-278 applicability: likely yes for consumer router + Wi-Fi host). Arrow EMS NC / MacroFab TX at +$5-8/unit premium.

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Stage 8 — Canonical BOM + GUIDE + STLs (2026-04-24)

BOM-platform.csv (in every Ultra), BOM-modules.csv (Iridium daughterboard + LoRa upgrade + UPS hot-swap kit + Starlink bundle), GUIDE.md (outdoor mounting + weatherproof cable management + Starlink pairing + LoRa community mesh joining + satellite SOS handoff), STL-OPEN-FILES/README.md (pole/post/wall/vehicle mount hardware + antenna mast clips + cable strain-relief — enclosure body NOT published).

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Stage 9 — HW↔FW (2026-04-24)

Full output: HW-FW.md.

OpenWrt 24.10 base + WanderOS-Ultra overlay (superset of WanderOS-Bridge-5G + adds multi-WAN priority engine, Starlink local-API daemon, Iridium SBD queue, LoRa mesh daemon dual-stack (Meshtastic + ChirpStack), MPPT telemetry, CAN bus driver, IP67 seal-state monitoring via internal pressure sensor).
Wi-Fi 7 driver mt76 for MT7996AX (inherited Standard).
Cellular driver: ModemManager + libqmi + libmbim for FN990Axx (inherited Standard-5G + WanderCar Pro-Fleet).
LoRa driver: Semtech LoRaMac-node + Meshtastic firmware + ChirpStack server container.
Iridium driver: AT-command-based SBD daemon (inherited WanderAway).
eSIM LPA: open-source lpac integrated with WanderOS eSIM Manager UI.
Secure boot via U-Boot signed bootloader + dual-partition rollback + TPM-optional (for HAVEN identity-aware defaults + tamper-detection).
22-test production bring-up (adds multi-WAN priority engine smoke + Starlink API handshake + Iridium SBD loopback + LoRa mesh range + CAN bus smoke + IMU calibration + MPPT charging simulation + LiFePO4 pack-health + IP67 internal-pressure-sensor baseline).

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Stage 10 — Gate review + service flow (2026-04-24)

GATE.md (EVT 2027-Q1, DVT 2027-Q3, PVT 2028-Q1, First Customer Ship 2028-Q2) + SERVICE-FLOW.md (IP67 re-cert on send-back + replaceable seals/gaskets + user-DIY accessories vs Tier-2 Ambassador modem/daughterboard swaps + 7-year parts + hot-swap UPS pack-rotation).

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Flags carried forward (consolidated)

#	Flag	Severity	Disposition
1	IP67 cert budget + enclosure tooling ($85-120k)	🔴	Stage 10 business-decision + capex plan
2	FCC Part 25 satellite-resale licensing if Iridium airtime bundled	🔴	AVOIDED by bring-your-own airtime posture; legal review $5-15k
3	4-carrier PTCRB cert in parallel (+ outdoor host delta)	🔴	$75-90k launch + $20-30k post-launch
4	FCC DA-26-278 classification (consumer router — likely yes)	🔴	US CM strongly preferred
5	MIL-STD-810G outdoor environmental cert (12-16 week lead)	🔴	Stage 7 + Stage 10; in parallel with IP67 + PTCRB
6	LiFePO4 UPS cert (UL 1973 + UN38.3 + IEC 62133)	🟡	inherits Bridge Full + Standard-5G HAVEN; $15-25k
7	PVD finishing vendor capability + 4-8 week lead	🟡	Stage-4 vendor RFQ (IHI Hauzer / Vapor / PVT)
8	Engraved inlay pinstripe UV-epoxy pigment vendor	🟡	Stage-5 RFQ
9	Ambassador Tier-2 workshop fixture investment ($25-35k/site)	🟡	Initial 3-5 Tier-2-certified workshops; scale as volume grows
10	Cellular 1×1 MIMO (per image) vs 2×2 industry-typical	🟡	Accepted for v1 outdoor/mast-advantaged use case; 2×2 may be v2
11	Starlink reseller agreement for bundled kit option	🟡	Business-development track separate from SOP
12	Iridium reseller/partner posture	🟡	Bring-your-own airtime = avoid Part 25; confirmed
13	Telit + Iridium + SX1262 aggregated-volume pricing	🟡	Stage-4 vendor FAE RFQ batch
14	Ship date Q2 2028 — long cert cycle	🟡	IP67 + 4-carrier PTCRB + MIL-STD + LiFePO4 + legal review = ~18 months EVT-to-ship

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Source-of-truth chain

hero image (2026-04-24, Michael) →
  _MANIFEST.md Stage 0 reconciliation →
    _DECISIONS.md (this file) →
      [BOM-normalized, BOM-platform, BOM-modules, COMPATIBILITY,
       SOURCING, DFM-DFA-DFT, THERMAL-EMC, COMPLIANCE, CONFIGURATOR,
       GUIDE, HW-FW, SERVICE-FLOW, GATE, STL-OPEN-FILES/README]

Original WANDERROUTER-ULTRA-SPEC.md v1.0 is preserved as comprehensive architectural reference; v1-image-locked decisions in this log supersede where they conflict (chassis form, price, SKU count, configurator complexity).

Why this way.