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Is one whole extra millimeter on the length of the pins really going to turn a safe connector into a shock hazard?

I think it's over-reacting, but then again...the pins on our plugs sometimes vary in length by a millimeter or two.

Some are slightly shorter and some are slightly longer.

All depends on the provenance of the plug and also I guess how much rubber is deposited around the pins (in the case of a molded plug).

Some replacement plugs usually have slightly longer (and thicker) pins. They help stay in the socket better.