Case fitting issues

[Flavor]

A new issue has showed up unrelated to hardware after getting everything hooked together. After taking out the battery and tearing it down when I try to boot back up the power switch will no longer work and it will only boot through plugging the Pi into a USB cable. Once I format the card and place the .img back on the card it will boot as normal. Not sure what is causing this but its frustrating.

I'm happy to hear that you got the plastics figured out. I can't say what the DPad issue is for sure, but my guess is that it might be something like the A-button issue. Perhaps your plastics or rubbers came from a run that was poorly made. Maybe, if I were you, I might consider buying another set and trying it. From our testing, we have some extras. I'll send you an email about that.

About the software, there is stuff in the /boot/config.txt that controls how the machine boots. I wonder if something in there is getting overwritten/changed. If restoring the IMG file fixes it, then I have to assume something in that (or maybe another) file is getting modified.