Are you guys saying specifically that the tip of the coiled tail cap spring is sharp? Seems like filing it down a bit would be easier than bending it down. Thoughts?
One would think, but it's not quite that simple. I did a combination of filing and bending. Luckily i have tiny files. Maybe it's me but if you just file it, its like sharpening a knife edge. So I filed to thin it down, then slightly bent it down to be just under flush with the next coil. There is no edge anywhere that could contact the cell.
Basically the end of the spring at the top is sheared off during the making process and it leaves a bit of a rough/sharp edge. Although I looked at my 2 spare mcclicky switches and they are the same. So This is just how the switches come. I guess I never bothered or had issues because i generally take the head off. The only reason why I checked this out is because of the one complaint without any pics to show anything.
This just seems to be the nature of a spring. However, it kind of depends on how the spring ends. I have some that are kind of flat where it's more obvious, and some that have a slight tilt down which makes it slightly better.
Here is my before and after pic: as you can see on the right, it is a perfectly smooth surface now. you can't see how I filed it and made it flush with the next coil, but you get the idea.