I hope you get to the bottom of this. It will be fun anyways. I look forward to seeing what you come up with.
Nonetheless, cleaning contacts etc, if one battery works without cleaning contacts and the other doesn't work as well there is an indication that one is marginal. Besides, I clean the contacts with an eraser. I would as soon use a battery that does not require filing the contact points or other extraordinary measures.
N
There now is a new type of rechargeable AA out in the market...with a higher voltage.
I just tried 4 in an led light to see how they would work...very nice.
Note: For those that don't know, LED brightness is due to the voltage present.. so Nimhs with 1.2 volts are no where as bright as standard batteries.. these new ones are slightly brighter than the standard ones... seem to hold a charge very well...and are roughly the same total capacity as Sanyo
Anyway, they are 1.6 volt batteries...require a special charger, and don't cost a lot more than regular rechargables.