The sled is very very tight, and i have to force it out and in every time.

On my mark 1, the side "bumps" scraped the sides of the player a bit too much and the player tended to get harder and harder to pull out each time as the scraping roughened-up the grooves.

My solution was to pound the bumps with a hammer to make them smaller, and then everything was fine.

The Mark2 solves this problem by cutting a U-shaped slot around each bump, in effect "spring loading" the bumps. Brian Mihulka made these cuts himself in his Mark1 sled:



In fact, I seem to remember either Hugo or Rob thanking Brian for the idea of springing those bumps. It's possible that he's the one responsible for that feature showing up on the Mark 2.

My sled is bolted into the car chasis:

Make sure that your bolts are not the source of the problem. The screws that hold in the hard disk tray on the sides of the empeg only barely clear those bumps, so if you add bolts to the equation, you have to make sure they don't hit the screws, either.

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Tony Fabris