Remove -CAP_TOL Z offset from cap translate; the recess in the case already provides the fit at Z-, so the offset was dropping the cap 0.2mm below the case floor.
@@ -145,7 +145,7 @@ module cable_cap() {
_bore_h = _cap_bore_h - CAP_WALL;
_bore_r = _bore_h / 2;
- translate([case_w - CAP_ENGAGE + CAP_EXPLODE, -CAP_TOL - CAP_WALL, -CAP_TOL]){
+ translate([case_w - CAP_ENGAGE + CAP_EXPLODE, -CAP_TOL - CAP_WALL, 0]){
difference() {
// Outer shell: hull between two square profiles
hull() {