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I finally got around to starting to build my ergodox from the April 2016 drop.
My 2u thumb get stuck half way up because the stabilizer is hitting the base of the switch. I looked more closely at my plate and the stabilizer holes are perfectly centered over the holes for the switch rather than offset as they are in picture 1 of this image:
My base plate:
Stabilizers hitting base of switch:
Is this whats causing my stabilizers to catch on the switch rather than pressing all the way down to the pate? What are my options to fix this?
Unfortunately I didn't think to check the alignment of the stabilizer holes before spray painting it black
That's pretty strange because even the pre-release photos from that drop clearly show the offset of the stabilizer holes. "Easiest" remedy I can see besides replacing the board might be to bend a new clip from a straight length of stiff wire, giving a little more girth around the switch body and potentially bringing the ends slightly in. Might be able to get away with just filing or melting the back of the switches if the tolerances on the stabilizer are low enough. The stabilizers fit fairly snugly but it seems like enlarging the mounting slot towards the outside would likely just make them fall out.
Have you already checked/dry-fit the switches on the PCB? Might want to make sure that isn't off too before doing any more with that plate... but if the switch holes are actually the holes that are offset, that is something you can maybe file one side of and not lose a lot of support.
Other people in this forum, including myself, are reporting the same issue with the stabilizer slots. I was able to work around it somewhat, although not completely, by filing down the insides of the plastic stabilizer posts. One of my keys still sticks quite a bit, even after filing down the posts.
Seems like a manufacturing defect. Has Massdrop support or Input Club done anything to resolve this?
This is only part of the problem. Mine does the same thing. When I have the stems all fully inserted, this does limit the vertical height and travel by a very small amount. But not much. The reason it sticks, is that the two outer "sockets" on the cap hang very slightly over the edge of the base of the stems that go into them. The socket is just wide enough that it catches on the edge of the plastic thingy with the stabilizer clip.