Nevermind, it was the plastic over the battery pack.
I didn't comment before because I knew it was only a matter of time before you figured out on your own how to access the batteries.
Now you have me really curious. The plastic cover? Over the batteries? Or do you mean the plastic on the batteries themselves were preventing a good connection?
The saber works now with batteries only, when not plugged in?
I hope so.
I love my diamond sabers! I hate hearing that other people are having problems with theirs. They are great sabers. They take a little time to learn all the ins and outs but it is time well spent.