After having some reassurance on the atty travel observation not being an issue for others and having some time to really look at what is going on under the hood, I am certain that the connection is good and not opening. Open at the atty connection was actually one of my first thoughts. I am convinced that it is just rocking because the center post protrudes form the bottom of the atty and contacts snug before the rest of the threads can be tightened. At first I thought it was the o-ring but same thing happens without it. The insulators appears to be intact on the center pin in both the mod and the RM2. Open at the connection is not completely ruled out yet, but not top of the list at this point...(I need to pick up a new properly working DMM soon).
The seller sent me 2 brand new springs with the mod. I'm rocking one of them right now. The one that came out doesn't look compressed compared to the new ones. I'm thinking the button was the problem. The top cap on the switch was so compressed onto the switch post that I had to mash it down hard to get it to contact the battery. After applying NERAK's paper wad solution to the top cap, the switch has travel to spare. The pin contacts the battery after about 2/3 of the button travel, leaving plenty of head room and I have not experienced this issue since.
I will be rebuilding this, but I am holding out for the new low voltage drop kit that is mentioned in this thread. I'm going to try to "paper wad" this thing until that happens. I'm already in the dog house with the wife for buying this used off the classifieds right after I had just spent a bunch of money on a large quantity of unflavored 100mg nic juice for the freezer in anticipation of the FDA vapocalypse. I'm grounded from the credit card for at least the rest of the month, maybe longer if the checks don't start coming in a little bigger and faster.
I want to give you a small caution here..... Keep an eye on the interior of your Reo. There is a gasket in the 501 connector. This connector is pressed into the Reo. It is possible that the previous owner attached an atty too tightly, or dropped it (which can also cause the jamming of the button topper) and jammed the 510 connector. If it starts leaking from the drip well, that is (more than likely) the problem. I have a grand, and my wife has 3 Reos and none of them have any atty travel, and are straight with the mod. If you notice leaking, you will need to send your mod to Rob to have a new 510 connection.