It is unfortunate, but screw manufacturers do not specify tolerances on 
the length of the screws, so yes, the length will vary from batch to 
batch.  If the "1/8 inch" screws were really 1/8 inch long, there would 
be no problem.

Since I build and repair a number of KX1s, I have ordered some black 
2-56 x 3/16 inch screws and some black 2-56 nuts from McMaster-Carr just 
for the purpose of repairing loose battery holders.  You can order from 
the same source, but you have to order a box of 100.

73,
Don W3FPR

On 6/7/2012 9:05 AM, VK7JB wrote:
> Chuck,
>
> Yes - grinding down the nubs was a bad move. I didn't measure my screws, but
> they were too short to even get one turn into the threaded hole. Like you, I
> suspect they are just too short for the job.
>
>
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