I just ordered cable and tips from Bill and put one together last week.
I spoke to Bill the other day about this cable and my not being able to get it to work. Funny cause I thought I had done everything correctly in making it. The ends are idiot proof. I felt like I was in the 3% bracket that Bill says can't assemble them correctly.
I thought I had done something wrong. I plugged it into my amp but I got no signal. It felt like it had inserted all the way because it was very hard to push into the jack.
So I took it the other day and tried the same cable in my old Yamaha amp and it worked perfectly. It still went in hard. I had after all assembled it perfectly.
So went back to my Line 6 and tried it again and it wasn't going into the jack all the way. It would seem the tip is the culprit. I pushed a little harder and it went in but it took some effort and I would imagine it will be difficult to remove. But it worked perfectly.
Like you I agree that the clarity and the power I got from the cable was outstanding! I was amazed at the difference. WOW!
I then went and made two short ones for my DBX 163A compressor connection in the amp loop. Dang what a difference!! I wish I would have bought some of this cable sooner. Outstanding results that are instantly audible.
The problem you are having I am afraid will happen to me as well as the tips seem to be over sized a bit. I am going to see if I can use sand paper and smooth the end tip. Maybe a little WD40?
Bill will call me when he reads this and I will ask about it.
I highly recommend this cable!