Here's a bit more info that might help diagnose this in some way. I measured the pin diameter of a hundred or so random sampled terminal pins and my typical pin diameter measurement was about 1.06 mm. A few of the pins were as thick as 1.10 mm and many were in the 1.07 to 1.09 range. My solution was to chase the holes with a 1.1 mm carbide micro drill using a jewelers drill press. Since I've been building some of prototype PCBs, I have most drill sizes up to 6.5 mm in 0.05 mm steps. I found 1.05 was still too tight for some of the terminal pins. While chasing the holes, I watch the drill shaving and for the most part, I only see the plating material. After chasing, I also check the continuity and resistance to make sure I have a good front to back connection. I haven't had any problems with using this process so far. Here's a summary of my experiences.
Last Year
I built 32 LEs last year for my display. I don't remember having any issues with the terminal pins fitting last year. However, they were snug and required a bit of force from time to time.
First Coop This Year
I bought 6 LEs in the first Coop this year. Two of the six required chasing.
My neighbor across the street bought 2 LEs for his display and I needed to chase both of his boards.
10 PCBs & Heat Sinks
I purchased 10 heat sinks and PCB between the first and second Coop this year. One of ten of those boards required chasing. Several of the others were extremely tight.
Second Coop This Year
I bought 6 LEs in the second Coop this year. Five of the six PCBs from the second Coop required chasing.
As a note, at this point, I have sufficient LEs for my display this year. However, I have several friends that may purchase LEs for their displays and I will probably help them build their boards. So I try to keep track of this if needed.
Hope this information helps and again, thanks for all of your time and effort.
