Need help, multiple problems w/FPZ

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For the Freeplay Zero, one big thing to check is where the back of the Pi Zero (where the 40pin header sticks out the back) contacts the shell.  This area can be very difficult to notice, but it can cause fitment problems.  As far as shells go, I've seen differences in this area, and some shells have extra plastic here that others don't have.

It can be difficult to tell if the shell is touching the back of these pins.  There are several things that can cause problems here.  

• If the Pi isn't fully inserted into the Freeplay board
  
• If the pin headers soldered into the Pi are sticking out too far on either side
  
• If the plastic shell has extra thickness in this area
  
• If the Freeplay board isn't fully seated down into the front shell section before putting the back section on
  

Check those things and maybe post some photos.  If you keep having problems/frustrations here, please also open a support ticket at https://www.freeplaytech.com/contact/