Hi guys,
First let me apologize for the loooong brb - couldn't get back on that night just kept getting "too busy", then was on the road for a few days. I've been putting all my money into vaping supplies & don't have a working laptop atm.
I ran off to try sucking the battery out, vacuum cleaner, suction cups etc. - that didn't work too well since I couldn't get a seal - so ended up putting in a 12v cooler overnight (no moisture) & the battery had risen level with the top edge of the case by morning, not enough for me to get a grip on the battery though, left it in the unplugged cooler while I was away & tonight when I got home the spring had finally pushed the battery up enough to get hold of it & wiggle the rest of the way out.
The bad tenergy batt is 19mm at its widest & doesn't seem damaged apart from the scuff marks that show where it was stuck. There is no way you would think this would get stuck, there is a ton of wiggle room (bottom is narrower than the top) until it reaches a certain point ....
Removed the spring & tried the different batts.
1 ultrafire slides right to the bottom
1 ultrafire catches with 3mm sticking out
1 tenergy catches with 4mm sticking out
1 tenergy catches with 17mm sticking out < this is the one that got stuck
(catches - just means feeling resistance & having to "push" battery in further)
So got a straight edge and lined the bad batt up - when the top touches the straight edge, the bottom is 3mm away - no wonder the damn thing got stuck if the case is 19mm. So just QC on the batteries, one that was ~1mm wider than spec, and pretty easy to test for from now on. Looks like height as well as width are pretty variable, the ultrafire that broke my Tenergy TL100 charger was 68mm + button top, max opening on the charger was 69mm minus contacts - well duh, lesson learned.
So from 2 companies 50% of my batteries were not within spec, only 0.5mm/1mm out but that can sometimes be enough to cause problems. Guess I need more batteries than I thought & more chargers
Going to go catch up on some sleep now.