I agree that it does happen here & there, I've had a couple of shorties that had one connector barrel ok, & the other a bit too small(measured with my calipers at about 3.9mm or so, while the good ones were more like 4.1mm). Doesn't sound like much of a difference, but using those newer male plugs(like these: http://www.tqrcracing.com/shop/produ....asp?p_id=7358 ) it's incredibly tight in the small dia. barrels(one one shorty, I even accidentally tore the casing of the pack apart slightly trying to get that one out of the barrel). Best solution I could find for it was to use the older style banana male plugs on the end with the small barrel(for me, I've almost always found them on the neg. side of the pack).