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Hi, I could need some helping thoughts, hands or calipers in solving the remaining geometry problems
I spotted with the electric plugs Sad

Please download the accompanying small demonstration file electric_plugs_geometry_problem.ldr
(which uses unofficial parts currently on the PT). It contains the simple assembly

1 7 0 0 0 1 0 0 0 1 0 0 0 1 4169.dat
1 2 0 -122 -1 0 0 -1 1 0 0 0 -1 0 512p01.dat
1 47 0 -122 23 1 0 0 0 0 1 0 -1 0 266bc02.dat
1 4 0 -102 10.5 1 0 0 0 0 1 0 -1 0 766ac01.dat
1 1 0 -94.5 18 1 0 0 0 1 0 0 0 1 766ac01.dat

This assembly is taken from set 7866, where it occurs in this form.

The following geometry problems can be seen here:
1. The central pin of the blue plug is smaller than the hole of the red plug where it should fit in.
2. The thickness of the red plug is so large that it collides with the green part: You can see the 2 parts intersecting each other.

I am not sure how to solve these problems.

Solving problem 1: this can be solved by either
(a) enlarging the pin of the blue plug
(b) reducing the size of the hole in the red plug
Solution (a) would require to touch ALL official parts having a hole for that pin, and that are MANY parts.
Solution (b) can easily be applied, as just the hole in this plug file needs to be adjusted.
So deciding between (a) and (b) is not only influenced by the real world diameter which can be measured,
but also by the amount of official parts that would need correction then.

Solving problem 2: this can be solved by either
(a) Making the plug a little thinner to remove the object intersection. In real life, it just snugly sits there touching the 512p01.
(b) Repositioning the plug sockets in the light brick 266bc02. Doing so will require adjusting all light bricks the same way (repositioning the plug sockets).
Remark: it could be that the plug sockets at the light brick really are misplaced in all official lightbricks.
This can be concluded from the fact that all have the same position for them, but just 266ac01 uses a different position.
Checkout the attached Electric.ldr.

I am a little lost and desperate here.
Folks, can you provide help or share thoughts?
here is a possible solution for problem 1.
I reduced the size of the hole in the plug
so that its own pin fits in there better.
This implements solution (b) for problem 1.
I went for this solution on the PT now because it doesn't hurt
and makes the part self-consistent without having to update TONS of official parts.

A later iteration can - if at all necessary - modify the plug's pin's diameters,
but I am not sure if that really is needed AND worth the effort.