Hmmm ... Methinks I can make a change with a file and various other impact instruments. We will report back if successful.
Please re-read TM9-243: Use and Care of Hand Tools and Measuring Tools
A file is NOT an impact instrument!
LOL you need to spend a day here.
![Laughing :-DD](https://www.eevblog.com/forum/Smileys/default/smiley_laughing.gif.pagespeed.ce._hfWAz_QHO.gif)
Comparing the two versions, I'm convinced the main issue is the way the older ones are curved and pointed. It's applying the force at a single point and if that point is not stable the part will fly off. The newer design has more surface area applying force since it's not applied in such a small point but along a slightly longer area.
So I plan on duplicating the bend to fix it, and filing the ends a bit to remove the sharp point. I will return with results only if I have success.
![Clapping :clap:](https://www.eevblog.com/forum/Smileys/default/clap.gif.pagespeed.ce.LImJbaO0yv.gif)
P.S. I guess that's why they gave a backup set of ends - so the user can figure out how to fix the design themselves.
![Laughing :-DD](https://www.eevblog.com/forum/Smileys/default/smiley_laughing.gif.pagespeed.ce._hfWAz_QHO.gif)