Thanks guys, used thier contact section and now chatting with Perseas, prompt reply and yes very helpfull.....
"A common mistake people do when they take apart the switch (even Scott did it as you can be see the deformed screw in the video), is to use non proper screwdrivers, usually smaller ones to open the negative post. This results in deforming of the slot’s lips, they become slightly raised up, resulting to micro arks due to point contact with the battery ’s bottom and the momentary released heat gives a hot button.
The solution is to take a flat surface like a glass and put on it a very fine grit paper, around 1000-1500 and thenn to smooth the screw’s head with very smooth circular movements, just like petting the head not rubbing it. The silver plated brass screw is a soft alloy and it doesn’t need much to become flat again. In case you overdo it and peel off the silver coating, no worries, the target is to make the surface smooth and flat."
I most likely did do the above and made the situation worse but my question now is I only took apart because of the problem so a few spare brass screws would give me peace of mind, maybe mine had a very slight "raise" to start with...?
Anyway helpfull information above for G4 owners...
