"I do have access to micrometers (tomorrow) so I'll check the physical dimensions as you suggest. But I don't think they're much different, if at all.
And it's not zero ohms because I don't have superconducting cables! Not even Monster claims that....
I measured 0.16 ohms between the connected ends and infinite resistance between the unconnected ends. " -
First of all, micrometers shouldn't be necessary - just holding a "good" connector up to a "bad" one should be close enough, expecially for body length. Diameter of the Mil connectors, which I really doubt you have, was just slightly under 1/4" and shouldn't make any difference anyway. It's the length I couldn't remember being different or not, and that could concievably change the contact surface mating between male and female.
Second, if we're going to split hairs I know it isn't really zero, it's just not ONE or FIVE ohms. Calling it zero is common among casual conversations. If I had really meant zero, I would have called it "less than 0.0001 ohms, or some other equally qualifying value, along with a tolerance, which must be included with any measurement to make it truly valid. What you measured is close enough that it should have worked. In all likelihood, unless you are using a $300 or more DVM with lead compensation or delta offset, a good percentage of that 0.16 ohms is caused by the meter leads or probe contacts anyway.
Third, I didn't realize you had separate inserts and direct outs, and incorrectly assumed that you were using inserts as direct outs by doing the first click thing...
And fourth, are you saying that now the cables work, or just that they did once when the pollen count was right and you only listened with your left ear while standing on your head, or what? If so, Rod Serling is on a different BBS,
www.twilightzone.com I think...
Seriously, about the only other thing I can think of is that the connectors have a wierd kind of plating on them that doesn't make very good electrical connecton - If they're no more reliable than that, I still stand by the Vaseline recommendation... Steve