window wont fit over channels

A quick learner from florida says:
October 1, 2014
Hello- I recently purchased the 29" series 380 balances. The sash will not go back in over the balances. All hardware and dimensions are accurate except for one; the original channel depth (not width) is 1/2". The depth on the 380 series is 5/8". It seems like the extra 1/8" on each side has made the opening too narrow for the sash to fit back in.

Greg C.
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Paul from SWISCO responded:
October 2, 2014
Thanks for posting, Greg. I'm sorry to hear you're having trouble. Could I see a couple pictures of your balance and the new balance side-by-side? That might help us come up with a solution.
A quick learner from Florida says:
October 2, 2014
Here ya go. New balance is on the right in all pics. I've added some 1/8" bar stock in the last pic to show the difference in depth.
User submitted photos of window balances.
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Paul from SWISCO responded:
October 6, 2014
Hmm... I feel like there should still be enough play in the sash to make up for the difference in the channel size. Have you tried shaving down the shoe a little? Give that a shot. Some older balances use a shoe with a depth less than 1" that isn't made anymore, and I think that's what you have. The tell-tale mark is the slot down the center. Most of the time our 15-005 shoe (which comes with our Series 380) works just fine, but in other cases it has to be shaved down a little. Let me know if that works!
A quick learner from Florida says:
October 6, 2014
I took another look at this over the weekend and did in fact shave the shoes a bit. This worked great. No need to hold it open with a stick any more.

Thanks again
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Paul from SWISCO responded:
October 6, 2014
Fabulous! Sorry again for the trouble.
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