Hitec has changed the case design for the new HS485-HB servos. It is now the tallest servo they make in the standard size format. They are a very tight fit for the brackets now. You can assemble the servo into the ASB-04 or equivalent as normal, because the bracket has some give and take. Just tighten the 4 mounting screws to take up the slack. We are looking into a couple options that will make them fit better. I’m looking into a button head version of the 3x8mm screw, and also a half height nut. One of these should alleviate the problem. I will keep this post updated as we figure this out. Sigh… 
I find it hard to develop a mental picture of what you are saying. If at all possible, can you post a few pictures illustrating the problem as well as the possible solutions? I’m assuming there is a small gap between the bracket ears and the bottom of the servo flange that can be closed by tightening the screws.
Just hold yer horses! Pics are coming. 
Something similar to this might work inserted from the inside out:
Yes, I have put in an order with my fastener supplier for something like that. Waiting for him to reply with what is available.
The button head screws will fit in the new brackets if assmbled with the head on the inside, but that almost forces you to use locking hardware on the outside because if the nut loosens up you have to disassemble the servo from the bracket to get onto the screw and re-tighten.
Another possibly viable option might be to press in a pair of PEM F-M3-1 flush inserts before the metal is bent.
http://www.pemnet.com/cad_library/graphics/f.gif
That would be the best option; however, I’m not sure how this would impact cost wise. I hear you about the hardware becoming loose, but to me, aluminum is sort of “grippy” meaning that with a little pressure between the steel button face against the aluminum, it will grip and allow you to tighten the hardware without having to disassemble everything. I don’t want to say with any sort of confidence this is the case, its something that would need to be looked into and experimented with.
Those nuts are cool, but not going to help much. I’m looking at about 6 thousand ASB-04’s already on the shelf. We keep a huge inventory to keep this stuff in stock. Besides there is also all the other brackets that work the same way as the ASB-04. ASB-15, 17, and 24. So the answer is in the hardware, not in changing the brackets. I have had really good experience with button head screws. They really grab when tightened. I just don’t have them in metric.
This is a rev of the servo? How much wider is the body?
If it’s really close, I’m wondering if simply making up a sanding block (sandpaper wrapped around a block of wood) and taking down the case a little on each side would help. I’d be tempted to file the brackets as well (but then I’m familiar with metalworking). Possibly not something you want to propose as solutions.
Issue a warning for that particular servo?
Or, It looks like just a small space between the ears of the servo and the bracket. How about some small spacers?
Alan KM6VV
Is Hitec planning to make this sort of change on all new servo models? How much of a change would be required to the ASB-04 and ASB-24 to accomodate this as well as older servos? This might be something to think about in the future.
Bad Hitec, making changes like this! 
8-Dale
I’m all over it. lol
Agree, it affects all designs that have dimensions using the other case design. I bet servo city is Angry.
It is a different new model to replace the HS-475/HS-5475 servos.
While it is rated a few oz-in more than the HS-x475 servos it also appears they added some cost saving measures like no rubber boot where the wire leaves the body.
The significant dimention that changed is the depth below the mounting surface. It increased by 1.48mm.
You can’t really sand 1.48mm off the bottom of the servo since that would put you through the plastic and probably start eating into PCB.
You can’t add height to the mounting surface because you change the distance from the top of the servo horn to the bottom of the ASB-04 so your C-brackets and stuff would then be too narrow.
to put this in perspective of volume, hobby robots are at best a niche in their sales and this is a low-end servo. The bigger r/c market will be pretty much immune to a change in this dimension. I can’t think of any plane I’ve ever built where adding 1.5mm to the depth of a servo below the servo tray would have caused an interference, especially any planes from kits or ARFs where you need to do your own radio install since the manufacturers don’t force any particular servo model or even brand on people.
This is disturbing as I really can’t see the sense in making a change like this in just one case. From a manufacturing aspect it is cost stupid to only do this to one models case. I would really watch in the coming months the cases on other standard sized servos coming in Jim. I’ll bet over time , as supplies of the older case style get used up, that you’ll see this showing up on other models. Like I said, to do it to only one servo model is not cost effective. I know cases are interchangeable on a lot of the standard servos.
I don’t think Jim plans to modify any of the exsiting servo brackets, I think instead he was looking into a hardware solution using button screws. I agree with you that conforming to the new case would not be a good idea.
I was forwarded to this tread. I was sold a Phoenix with HS485s with this problem. Has anyone found a solution? I’m assuming not, or I suppose I would have been given the solution along with my kit. So, I’m sitting here staring at a $1k pile of aluminum and servos that I can’t finish assembling. I have the 12 other servos and electronics mounted, but the 485s seem completely unworkable as they are. What’s the answer? How about some replacement servos that actually fit? – Win
For starters nobody at Lynxmotion is likely to give you an answer until Monday morning.
Next up we find Hitec has replaced the 475 servos with the 485 servos in their product line.
Lynxmotion was effectively blind-sided by the change in the mechanical package of what they were told was a drop-in replacement.
Lynxmotion is currently working on a solution for their customers.
My understanding is it is 3mm x 8mm button head screws to replace the supplied pan head screws, and they mount in the opposite orientation with the head inside and nut outside.
I have successfuly done this same approach with #4-40x1/2" button head screws and locking nuts on a ch3r chassis.
Using a normal #4-40 hex nut you would probably need to use #4-40x3/8" screws.
I believe there are some significant logistics involved for Lynxmotion with buying the hardware, packaging it up, and getting it out to their distributors, however there is no doubt at all they are giving it their full attention. They have over 6000 brackets in stock so the task is not trivial.
Again I would remind you that the Lynxmotion staff does not generally participate on the forums during the weekends so any sort of official answer or resolution for you will more than likely have to wait until Monday morning.
I understand that Lynxmotion likely won’t reply till Monday. But I do appreciate your info. I’ll look around here to see if I have some hardware to make this work, but it’s unlikely.
I’m blowing off some steam. This is obviously a known problem, and they sold me a kit I can’t build. Unacceptable. A little info from them before I gave them $1k would have been appreciated…I likely would have waited until they had a solution to this. I even rushed the order so I could finish building it this weekend for a specific purpose this week. I’m not sure what possible reason they could have to do this. I’ve been a good customer to them…this being the most expensive item I’ve bought from them and they pull a stunt like this. Not a particularly professional move in my opinion. --Win