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Phew, Based on the title I was wondering if I'd have to move this thread to the non-public forum, haha.

You could try lightly sanding the outside of the handle port ring with fine sandpaper. Remember you can always take more off, can't put it back on. Too lose is also a problem.
 

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I had the same issue. Put a light bit of silicone spray in the Male end and it has been perfect since.
I have the same problem with my OpenEVSE charge station; the J1772 handle I got from Quick Charge Power is hard to plug in. I've sanded the outside of the handle port ring without success. I've also used silicone spray, but that seemed to make it worse; almost seemed like it made the plastic swell a little bit.

I've learned to align the handle to the port as precisely as I can; that's about the only thing that seems to work. I've had no such problem with my old Voltec EVSE's J1772 handle.
 

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I have the same problem with the J1772 plug on my OpenEVSE. I have been using a very light spray of WD40 on it. After a year or so it has finally improved a bit. I have never had a tight fit problem with the J1772 plugs on ChargePoint or EVgo stations.
 
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