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Good point. I had assumed that the couplers were weakening/starting to flex, but also possible (and maybe more likely) is the BODY tube of the next Segment may be deforming/widening.I would imagine you could use the same CA/dry/sand method first used to make them slide in and out, but then could it be the tubes themselves becoming wider? If so would it be wise to try applying the CA to the inner tube and sand down or is "the damage already done"?
Once I finish mine I'll certainly post photos and try to keep track if I start seeing the same issue. Since I'm still new enough to keep track of my launches (15 total as of this writing) maybe I'll also be able to report when this issue begins to present itself, if I too see it happen.
i have read that a number of people on this forum (I think including @hcmbanjo ) will dribble a bit of thin CA on the inside forward edge of the body tube on each rocket to strengthen it, so applying the CA to both the coupler and receiving segment with judicious sanding may be the trick. It’s a bit touchy, you need the joints in boost mode to be solid enough to keep the rocket “straight” but loose enough that ALL THE JOINTS and the NOSE CONE separate with one ejection charge. Once there is a separation between ANY segments the body tube compartment decompresses, so separation of remaining segments is dependent on combination of inertia And drag. That said, usually works!