I just finished assembling an AL5A kit and ran into a problem. The HS-485HB servo for the “elbow” joint dosen’t fit. I see a shorter nut was included for this slightly taller servo but this appears to be a fix for using the HS-485HB servo for the “wrist” instead of the “elbow.” I installed an HS-645MG instead but I’m still curious about the HS-485HB problem.
Step 13 is where I encounter the problem: lynxmotion.com/images/html/build140.htm
Looking forward to having some fun with the AL5A! 
This is one of those cases where you just tighten everything down. We could put a button head screw in there, but then we would have to include a hex tool. The only arm this effects is the AL5A. We though it was ok to just crank down the hardware, but after further consideration, sigh, we are in the process of upgrading the elbow servo to the 645 in this kit. The price will go up a little though. Sorry for the trouble.
Yikes! That sounds like nails on a chalkboard to us OCD perfectionists 
No problem. The arm turned out great with the 645 and I’m very excited to start experimenting. I just needed an answer to this problem as a sanity check to make sure I wasn’t overlooking something obvious.
Yeah sorry. Hitec really blindsided us on that 485 servo redesign.
The AL5A and AL5D are interesting.
Instead of the counter spring, have you experimented with a counter weight instead?
Alan KM6VV
