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Update: I got 3" 8-32 screws to replace the stock transformer screws, and the raised the transformer out of the chassis recess by 4 additional nut heights (about 12mm). I must have done the math wrong originally, I have way more space than I thought I would doing this method. Currently it's using screws from Lowe's labeled as "zinc" screws, but down the road I'll be replacing those with stainless steel to match the rest of the hardware. Just wanted something cheap for now until I can place an order with McMaster-Carr. Not looking forward to undoing and redoing the nylock nuts though...
In doing this, the leads from the transformer are now in a place to chafe against the chassis edge. To fix that I installed some grommet edging. Down the road I plan to get some with good adhesive on the inside to make sure it doesn't come off when it doesn't have the wires blocking it. It sticks for a while currently with the expired adhesive mine has, but eventually over an hour or so it will release and straighten out. Another option would be to use something like Loctite 422 to stick the polyethylene grommet down for good. You might be able to see in the pictures where the cloth insulation has already chafed/been cut through. Luckily there is plastic insulation underneath. Another concern I have for the leads is bend radius. I think I pushed it too far here, and should make the cutout in the chassis a little bigger.
After installing the nylock nuts on the transformer bolts I started working on the power supply board that's supposed to mount to the bolts. Took some measurements, carefully marked out dimensions on my FR4 sheet, cut, drilled, and.... nothing fit. Nice. Manually made some holes bigger, and now things fit. This will be the insulating card to keep the power circuit card from shorting to the transformer bell.
In doing this, the leads from the transformer are now in a place to chafe against the chassis edge. To fix that I installed some grommet edging. Down the road I plan to get some with good adhesive on the inside to make sure it doesn't come off when it doesn't have the wires blocking it. It sticks for a while currently with the expired adhesive mine has, but eventually over an hour or so it will release and straighten out. Another option would be to use something like Loctite 422 to stick the polyethylene grommet down for good. You might be able to see in the pictures where the cloth insulation has already chafed/been cut through. Luckily there is plastic insulation underneath. Another concern I have for the leads is bend radius. I think I pushed it too far here, and should make the cutout in the chassis a little bigger.
After installing the nylock nuts on the transformer bolts I started working on the power supply board that's supposed to mount to the bolts. Took some measurements, carefully marked out dimensions on my FR4 sheet, cut, drilled, and.... nothing fit. Nice. Manually made some holes bigger, and now things fit. This will be the insulating card to keep the power circuit card from shorting to the transformer bell.
