See the difference in outside diameter of the carbon where it meets the EVA. That’s driving me insane.  You guys have any tricks or suggestions?

thanks 

Cut back the EVA and the grip tenon in 1/16" increments until it fits flush.  Without a lathe it may be difficult to get a straight cut on the EVA.  I've never had your case but often the butt cap is larger than the grip with CFX carbon fiber from Mud Hole.

I would contact the source, show this pic, and request some action.  I expect they will select one that fits better and send it out.   At least it would be worth a try before investing a lot of time risk.

Thanks 👍

Since its EVA...you could wrap some tape around the blank and make the EVA expand...it wouldnt take much.

Not sure I would use tape, especially if there is a chance of water immersion, thread and some kind of watertight finish applied would be my approach to increase the tenon OD, remember EVA does not expand without also thinning so it will be an uphill battle to get that little bit of increased OD taking more to do little. Frankly, I can't imagine how anyone could expect a perfect match up knowing the materials and process. it's not like it was made of a single, solid material like cork, eva, wood, etc. There are certain imperfections involved in the carbon skin/ foam core and different butt caps are not built with identical OD, metal, rubber, eva caps have no standard OD, everyone does the best they can not knowing what type of grip they will be attached to. No standard = no chance of perfect fit universally.

5 hours ago, spoonplugger1 said:

Not sure I would use tape, especially if there is a chance of water immersion, 

 

Electric tape.

 

"EVA does not expand without also thinning "

 

Spencer...Did you look at the picture? We're talking about 1 mm. How would anyone be able to tell the difference once its glued together?

Maybe we are the same path, looking at it from another angle. All I'm saying is when you install eva grips and you slide the grip into place instead of first reaming to fit, the difference you will see in diameter after you are done will be hard to notice, as the eva expands in OD it also thins materially and therefore stays very close to the OD you originally had. Making up the difference to get what you want may take more tenon size difference.

Spencer...OK...I see what your talking about...the OD may not expand like one would think.

The blank diameter itself might stretch the Eva enough to mitigate the size difference. 

tape should work and if you epoxy over it all it'll be waterproof.  

I do as Mike K. does. I made a gizmo to spin the cap with a drill and cut it with braid. You might have to shorten the tenon as well. Very likely. A day or two late with this I now see. Lol