Chassis Disc Not Fitting Into Hilt Style 5

[grAfLEX25]

I made the mistake of not testing my chassis discs before assembling my chassis and wiring my board While attempting some cram-fu, I realized that my first chassis disc would not fit into the body of the hilt. It seems to get stuck right where the threads end and the inner 1.25" section begins. I thought there might have been a lip inside the hilt, but it feels perfectly smooth. I don't know if it matters, but I'm using the NBv3 disc with an 18650 battery. http://www.thecustomsabershop.com/Ac...k-S3-P813.aspx
I measured the disc and it seems to come in just under 1.25".

I tried fitting some other discs I had on hand like the PRIZM with 18650 batttery http://www.thecustomsabershop.com/Ac...k-S2-P768.aspx into a Hilt Style 3 I had from my first Sceptor build (glad it had a modular chassis) and it seemed to go in perfectly fine with even a bit of room to spare.

Is it possible the inner diameter of the Hilt Style 5 is just a bit off? At first I suspected my chassis was not straight or somehow messing with the fit, but I got the first chassis disc off the NBv3 and past the wires and it was clear the disc would not fit into the body. Any help or suggestions is much appreciated.

[Zzan]

Compare the one you got off your chassis with the ones that fit. Is there a major difference or is it just minor that you could fix with some sandpaper around the edges of your discs?

[grAfLEX25]

I'm almost certain the issue is with the body of the saber. I cut out my soundboard and chassis and tried to test fit my other chassis discs and none of them fit. Conversely I put the NBv3 discs that didn't fit into my Sceptor lightsaber and those fit no problem. I tried some clear tube guard http://www.thecustomsabershop.com/9-...bes-P1009.aspx in the Hilt Style 5 and that was too tight as well.

I took Zzan's advice and test sanded a chassis disc using 150, 220, and 325 grit sandpaper and was able to get it to fit nicely into the hilt in question.