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At this point its all guesswork since none of us are designing this thing, however with that said, my guess in this case is based on the fact that this thing is essentially a small bit of spring wire that pops into a groove.

Most likely its not very stiff since its only .8 mm wire (thats only .031 inches), my thinking is they assume the wire will distort during assembly and will allow a part that is .25 mm out of flat to still spring into the slot, however the wire thickness is critical because the slot is kept to a tight tolerance in relation to the wire size.

In this case it wouldn't be out of the realm of possibility that the tolerances shown not only were intended but do in fact make sense.
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It's a valid question. If they are sorting with a block that's slot width is greater then the low limit size of the actual mating part slot, then there's going to be a problem.

On a side note, Tom, you Fleckhead you, I ran across a video on You Tube with the Dave Matthews Band, (now don't start hating on me yet,, there's more,) with Bela Fleck and the Flecktones sitting in with them. Bela and Victor play about a 10 minute duet in the middle of the whatever tune they were playing that could only be described as improvisational genius. Tom, if you haven't already, track it down and give it a listen.
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