Are you using the Force Action lightsaber board or using the new 2010 Hasbro boards. The 2010 Hasbro lightsaber hilts are a lot thinner that the older models. It is with the 2010 models people are having problems with, the relay works great with the older models. I personally have not tried a relay with the 2010 models, I use the transistor set up with them.
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