Custom Control Panel (Wood) Burton’s getting “Caught”

[obizues]

First: The buttons are all the same with the same switches and same LED on them. They all had the same size hole saw used for the opening.

When I push down on a few of my arcade buttons some of them get “caught.”  If I push harder it will eventually go further down and make a sound like the plunger is caught on wood.

Most of the buttons, however, work just fine, and they don’t have a problem when they are uninstalled.

What could be causing the buttons to get caught when they are placed into the wooden holes?  The plunger is inside the shell of the button’s cylinder.

[RandyT]

If the button are the type which have a plug-in style LED, make sure the LEDs are fully seated and not loose.  The vibration from hitting the buttons could cause them to be unseated and get cocked in the holder, which would lead to eventual plunger interference.  If they don't seem snug, remove the LED and look at the little fingers in the socket.  If they appear to be spread a bit too far apart, insert (with power off, of course) something into the socket to bend them inward toward each other.  This will tighten the hold on the LED.

Also make sure that there isn't something in the plunger, like plastic flash, which is causing the inner diameter to be smaller than it should be.

[obizues]

Also make sure that there isn't something in the plunger, like plastic flash, which is causing the inner diameter to be smaller than it should be.

Thanks for the insight, what is a plastic flash?

[RandyT]

It is the remnant of plastic which finds it's way past the mold seams.  There is also the possibility of sprue which has not been cut off fully.

Basically, look for anything which is sticking out, and / or in the path of the plunger parts.