My Ops-Core helmet showed up unannounced yesterday (@TNVC you forgot to send the tracking #) so I popped my G11 out of the Nightcap and tried to put it on the helmet.  No joy.  Using my digital calipers I measured the plastic thingy that was already in the helmet's shroud (see pic) and compared it to the G11.  They are very close; maybe only a few hundredths of a inch different.  

After forcing the G11 hard enough to remove a few slivers of plastic inside the Ops-Core shroud, I got it slid in and it seems to work ok.  But should it be this much of a bitch to install?  It's a smooth plug-and-play fit on my Nightcap.

They probably got tired of people like me complaining that it was too loose. Plastic is harder to keep within dimensions than aluminum is. I would prefer that they err on the tight side.

If I had to choose between too loose and too tight, sure.  It is unreasonable to expect it to "just work"?

I do not consider the Bump Helmet to be the premium piece of gear that others here do. For the money charged, damned right it should work. From my background in manufacturing I have an understanding of why it is harder to do than it seems like it should.

All of the premium line stuff from Ops-Core has performed admirably for me, right out of the box. The aluminum shrouds from Ops-Core are excellent. I took the liner and ARC rails out of my bump helmet and dropped them in a different shell with an aluminum shroud. I also upgraded with Oregon Aero and old black MSA pads.

Thanks for responding.  I thought that tagging you @TNVC meant that it sent you an email notification.  Am still learning how to use the messenger system.

Appreciate your extension of the RMA offer.  Let me run this setup a bit longer and decide if it bothers me enough to go dark for a few days while it's off at summer camp.