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That slight mismatch adds to the overall positioning error
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The first step was to get all the relevant dimensions from an existing pack.
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On the bright side, it’ll be a lot easier to bike across the bridge…
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Grab a screw in a pin vise, brace it on the bench vise, and file off everything that doesn’t fit:
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I’ll probably end up using some bendy wire anyway.
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Those large eyespots trip your protect-the-baby response every time.
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Come to find out that the new gratuitously gold-plated 2.5 mm plugs in my stash have a slightly thicker front plate that doesn’t quite fit into the recess
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Trim it with tinsnips (or a shear if you have one), then introduce it to Mr Belt Sander.
The Smell of Molten Projects in the Morning 