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Posted

It's a difficult part to engineer I imagine because the plastic has to flex to allow a bar to be inserted, and the opening has to be slightly smaller than the bar's diameter to keep it held in place. So just having the bar in the clip was putting stress on it. Add to that the problem with the reddish brown color and this is probably the most fragile LEGO part in production.

They have redesigned the clips many times over the years and still do not seem to have solved it.

Posted

I believe minifig hands are thighter, though.

When I experimented with the slightly-smaller-than-bar 3mm batteries that power LEDs, I found that they were very loose in stud holes, tight enough in clips, but pretty tight in minifig hands, like designed for them.

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