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Any ideas?

You should probably put your bigger player on a low-fat diet, and make sure it exercises regularly. For low-fat music, I would suggest acoustic sets (Leo Kottke, Nick Drake, Johnny Cash). You should alternate with speed metal for the ideal workout scenario, and make sure you press the buttons a lot. Maybe leave the player playing overnight?

Another alternative would be to wash the bigger player in hot water and dry it on the hot setting in your dryer.

I've also heard that as your player gets older, it will shrink (from old age).
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Mark Cushman