Ok, so the engineer at Red Sea deserves a throat punch. Maybe 2.
This is easily the most over engineer piece of aquarium equipment I've ever seen.
So it turns out there are two different size screws. If you peer into the holes with a really bright flashlight, you can see some of them have silver threads and some have gold. The gold threads work with the finer pitched screws and vice versa with the coarse screws in the silver holes. Aye yae yae.
Anyway, got it back together as much cussing and screaming. This is the most user "unfriendly" thing I've seen in a long time.
The pins on the the canopy are a bear to pull out. The screw caps were a total PITA x10. I've already mentioned the two types of screws. Who thought that would be a good idea? The ballast layout is so tight, that was equally unpleasant to work in there. Getting the two halves back together felt more like a magic trick. There are a couple dove tail connections on the back half that sandwich the top and bottom together. The timer side, no problem. The other side? Wow, that by my measurements shouldn't even fit together. I kept play and playing with it and somehow, someway it popped back together. I didn't dare take it apart again at that point. The fan covers are a real treat too....
I almost threw a complete hissy fit when I put it back on the tank and the lights didn't fire despite testing it 10x before putting it back on. I run a neptune controler. Pleased with my work, I hit the on button for my lights on the dashboard and nothing happens. Right before I completely melted down I realised I forgot to hit the on button on the timer
If I have have a problem with these lights again, I'm gutting the canopy and installing Steve's LED kit. I wasted about 4 hours just changing a ballast.