Krunch1701

You're right, I misread the post about the movement of the switches, but it doesn't change the fact that the switch thread and handle nut are different sizes. And I've confirmed this today: I ordered a set of M7 X 0.75 X 2mm nuts from Amazon, and they fit the NKK S2AL switch perfectly fine. No binding or cross-threading. I suggest you do your own research to confirm; the nuts I bought are so short that I don't know if a longer M7X0.75 nut would still bind a bit, or if an M7 X 0.8 nut would be better. Like I said above, I could tell the threads were incorrect *the first time* I screwed one of the handles onto the switch. Additionally, after I had screwed the handle on, then attempted to remove it, the plastic handle came off but the brass nut stayed on the switch - I had to get a pair of pliers to take it off! I'm surprised you guys didn't observe any of this yourselves during development.

The reason the gear and hook switches are "rolling" is because they are using mismatched threads. The brass insert nuts in the handles are M8X1.25 threads, while the actual switches are another thread size. The two switches are NKK brand, S-2AL, but none of their online specifications state the plastic cap thread size. I have a complete set of thread gauges, and the switches do not match up with any standard metric or imperial thread size. Using some printable pages from boltdepot.com, I'm guessing the switches use a very atypical M7X0.8 or M7X0.75 thread. There are M7X0.75 tap & dies, so I will order one and see if it confirms the size. Everyone knows you're not supposed to mix nut/bolt thread sizes because they're not going to seat properly, and in the long run you're going to damage the threads on one or both of the fasteners. The fact that the Total Control guys didn't approach this correctly is mind-boggling. It's Mechanical Fasteners 101. I mean, I could tell the threads were wrong as soon as I screwed on one of the handles, it's that obvious. So now with this button box, if you choose to regularly put on and take off the handles for whatever reason, you're going to damage something. Crazy.

I think you're an hour ahead, because as I write this, greenwichmeantime.com says it's 1:42pm GMT, 2:42pm London.