Tuning Impact mk2 power plenum 720 install issues

I was installing a PP 720 on a friend's Impact mk2 with the small plenum, and ran into a couple issues. First, the "valve tube end"(part 101 in M3 manual) was too large to fit into the block. My friend called UA(where plenum kit was purchased) to get the correct part that fits the earlier guns where this is an issue, and for some reason, couldn't get any help. I think they were insisting he had the correct part, even though it definitely is too large to fit. He then called FX, and they didn't have any, but said they would send a sanded down one to him. I figured I would go ahead and sand this one down in the mean time to fit. I sanded what I thought was just enough for it to fit, and it is snug with no wobble. Well, it leaks like crazy there when I try to air the gun up. The only thing I can think is maybe I sanded the end or the ridges by the o-ring grooves a little too much. There really isn't a whole lot going on right there as far as sealing surfaces go.

My question is this: Do you guys think I just messed up on my sanding job, or is there something else I should be looking for? Have any of you guys sanded this part and had issues? It would have been a cake walk to fix, were it not offset, because I just would have chucked it into the lathe... I tried changing the o-rings, and slightly larger ones will just get cut up. I also replaced the big o-ring on part I sanded too. It is definitely leaking where E101 goes into the block. I didn't think I sanded it so much that I'd get leaking there, but I most certainly could have. The part from FX will show up eventually I'm sure, but I just wanted to make sure I'm not missing something else here. I'm not an Impact expert, and have never kept up with all of the little things concerning them whole lot. I have done a ton of tuning of air guns, including my heavily modified Maverick. I'm just not as familiar with the Impacts is all. I feel pretty sure my issue is with E101, but any input would be appreciated!
 
I have a MK2 (March 2020) and I wanted to do a power upgrade/machining, including internals in the power plenum, but I didn't wanted to alter the original parts so ordered a new PP kit. When all the machining on parts were ready to replace/install only then I realized the new PP doesn't fit plug-and-play, the plug OD was a difference about 0.100 mm. Instead of sanding I toke a flat screw driver and helped enlarging the hole ID for a hair.

Now, you had sanded the OD....there is a difference between sanding and sanding and sanding. Have you sanded before anything precise?

A picture would help.
 
Sorry guys, I don't have any pictures, and I don't want to pull the gun back apart again, until the new piece arrives from FX. Besides, we all probably know what the problem is. That being, I probably sanded a bit too much off somewhere on the part. I tried to sand the bare minimum to get the piece to fit, but I must have gotten part of it too much. After all, sanding anything by hand isn't exactly an exact science. I don't consider sanding by hand of any sort precise work, no matter how careful. Precise work happens on the lathe ;) I mainly wanted to make sure there wasn't something else I should be looking for, aside from the piece I sanded.
 
I had the same trouble, found it was just a couple thousandths bigger and sanded it to fit, leaked on 1st try but does not leak now. Mine damaged the o-ring on assembly so I broke, sanded, the sharp edge on the end of that slot where the o-ring enters the bore, lubed the bore with heavy silicone oil and greased the o-rings. To assist assembly I take the clamping bolt out and put it in the opposite side, place a small piece of aluminum in the slot so it doesn't protrude into the bore and tighten the bolt into the flat aluminum to spread the clamp area a touch, but not too much, don't want to break it.
 
You guys have got me thinking I should try the slightly larger o-rings again. I did lube everything with silicone. If can get something to "fill" that slot, I may be able to get the larger o-rings in there without them getting cut up. That slot is where the larger ones get pushed up, then cut, so that is definitely worth a look. I just have to motivate myself to take the gun back apart again now. I may give that a go later on tonight. Thanks for the tips guys!
 
I believe it's a problem with the pre power plenum mk2s and earlier, but I could be wrong there. I tried everything to get the slightly larger o-rings to work, but I just couldn't get it in without cutting the o-rings on assembly. I tried putting something in the slot, but it just ain't gonna happen with the o-rings I have anyway. I'll try it again when the FX modified piece shows up.
 
One guy suggested to install the screw to tighten the action to the power plenum in the opposite side and use it to spread open the action enough to get it to fit and then remove and reassemble it I don't know it that will work for you or not supposedly the clearance issue is .003 to .004 of a inch or a .1 of a mm your sanding should of took care of that I would try spreading it so you don't cut the orings if you have same trouble with the piece from FX