Here's what I discovered today. An inner sleeve drilled 1/4 left, 1/4 reverse was actually slightly larger than the other inner sleeves I regularly use (I use o/o, 0/--1/4 reverse and 1/4 left 1/4 reverse all on a regular basis, the first two being the most often used). My driller reamed out one of the balls outter sleeve and it was able to accomodate the 1/4-1/4 sleeve o.k. but not as effortlessly as I'd prefer.
So, this explains why "all of a sudden" the inner sleeve wouldn't fit. It was simply due to changing over to the slightly larger one. Since I have a very large inventory of equipment (
http://img207.imageshack.us/img207/9214/img4902bj8.jpg) and tend to rotate it quite often I mever caught onto the correlation.
The strange thing is that about half my balls had the switch grip installed by another driller and all the inserts--even the slightly oversized one--fit in those balls with no problem. In fact, many of them lock into place with not much more than a feather touch while the other drillers go in much stiffer with more resistance.
Both these drillers are top notch but the one whose inserts fit with no problem has been doing the switch grips for a much longer time. I think it's a matter of procedure. We'll figure it out.
Thanks for everyone's input.