The tight push-fit tolerances in the 2017 Dark Imperium box set are a well-documented technical quirk across the Warhammer hobby community, modeling forums, and build logs.

When Games Workshop transitioned into modern push-fit (Easy to Build) sprues for 8th Edition, the manufacturing tolerances on the male alignment pegs and female sockets introduced a few specific mechanical issues:

1. Hydraulic / Air Lock: The cylindrical pins fit into blind holes with almost zero clearance. When pushed together, trapped air in the socket pushes back against the pin, creating resistance. If plastic cement is applied into the socket, the liquid has nowhere to displace, preventing the two halves from seating flush and leaving a permanent hairline seam along the armor or torso.
2. Friction Binding: The surface area of the longer, un-tapered pegs creates enough friction during a dry fit that parts frequently bind halfway in. Attempting to force them often stresses the surrounding plastic or snaps the pin inside the socket.
3. Common Community Fixes: Modelers quickly established the standard prep routine: snipping the tips of the pegs at a 45° angle, cutting a tiny longitudinal relief slit down the side of the peg to allow air and excess glue to escape, or clipping the pegs entirely and relying solely on plastic cement along the contact seams.