Mistake How I fixed it
Connected the shift registers to low frequency MCU pins instead of high frequency ones This turned out to not cause too much of a problem, but it results in more interference in the wireless signal when the lights change
Did not follow standard practices for reference designators on the PCBs Did not fix
Placed a diode such that the diode legs would poke through and interfere with one of the stabilizers Cut the legs short and carefully soldered it perfectly flush
Somehow forgot to add a bolt hole in the left switch plate despite running interference checks Put the plate in a mill and drilled the missing hole
Missed the same bolt hole in the 3D print directly above said plate Added the hole and reprinted it
Assumed the power switches I had had a circular mounting geometry instead of checking carefully and realizing it was the union of a circle and rectangle Filed the corners off that part of the power switches
Forgot to consider whether any of my components would short against the bottom of the case Added a layer of foam between the PCB and the case
Thought that soldering jumper wires to small SMD components by hand was a good idea Spent a couple hours on extremely finicky and fragile work
Neglected to consider whether my soldered connections to the LED indicators would short against the top of the case Taped a plastic film between the indicators and the case
Forgot to leave clearance for the wires going to the power switch Reprinted battery holder with channel for wires
Neglected to consider wire management inside the case Reprinted battery holders with clips to hold wires
Counted keys wrong and did not order enough hot-swap switch sockets Bought more sockets
One key didn't work because a bent switch pin wasn't correctly inserted into the socket Replaced switch
Neglected to consider before manufacturing the case whether a metal case would block a wireless signal Drilled a hole in the case next to the antenna and added a plastic window there instead
Did not test how bad the signal integrity issues were before drilling that hole There's not really a good way to fix this one, but things worked out in the end
Drilled the hole with a handheld drill, leaving me with quite non-circular holes Tried to clean it up with a file, but not too much I can do about this one
My sheet metal bends' variation from the way they were designed was quite high. I should have practiced more on scrap metal. Filed down the various tabs until they were even; tolerated the remaining imprecision
Did not realize I couldn't bend the angled corner tabs on a press brake Bent them with pliers
When copying a part from the right to the left half, got my geometry mixed up Reprinted parts
Used too thick of wires going to the power switch; excess strands that couldn't fit through the through holes on the PCB shorted to each other Reworked with thinner wires
Numbered the status LEDs from the inside out instead of consistently left to right. Having "low battery" be the rightmost indicator on both halves would have looked better Did not fix
Did not check which status LEDs were supported by ZMK before finalizing the case design Gave up on charging indicator lights and made custom firmware to drive the rest
Tried to avoid having to understand the internals of ZMK by vibe coding the firmware extension Learned what my code was doing well enough to fix it with help from the model