It's not the plating as I remove the nickel plating the Switchcraft comes stock with.
My apologies Grover. Nice to see you again.
I have used Switchcraft parts before, in very high current applications. They are the only contacts that can take the current because they are nickel plated copper alloy not brass or steel. I was assuming that you plated over the nickel because removing it first is a pain in the butt and expensive to dispose of the nickel waste. Just curious if you have compared ID before and after your plating process?
I used my Grover cables as source switcher for a while, they weren't too tight. But that was 3 years ago, on WBT RCA connectors. They were snug but not too tight on SB3 either. Maybe something has changed.
Here's the specsheet for the plug:
http://www.switchcraft.com/products/jack-143.htmlPDF drawing:
http://www.switchcraft.com/products/pdf_files/jack-143_schematic.pdfNo sleeve ID dimension is given. It is designed to spring so tolerance is not as critical, unless you approach the spring limit, which is what's happening to Shep and Mike.
OD of my SB3 analog output (steel) jacks at 0.327"
Well worn gold plated WBT jacks on Manley amp inputs 0.325"
New unused Switchcraft RCA female jacks, gold plated 0.326"
A different Switchcraft jack just shy of 0.324" this one is often too loose for non clamping plugs, it would fall off with gravity, but still makes contact, probably high impedance.
WBT NXT RCA jack 0.329" but it's plastic so it gives with pressure.
So just 0.001" does make a big difference in the feel of the fit. It is hard to make pressed metal parts within a smaller tolerance than +/- 0.001." Temperature variation of the metal and pressing dies could cover that tolerance. But the plating thickness is pretty important.
Switchcraft was always very helpful when I had technical questions for them. Maybe you can ask Mouser if you can get unplated plugs? Mouser has good relationship with them.
It is difficult to measure the ID of the plug sleeve with standard mics because the pin is in the way.