Hey guys -- I've been reading all your concerns and have been taking note of what's being said. There definitely will be a revision in R2 to address these issues. I'll also be talking to Gateron to see what changes are possible for R2. I'd like to also mention that I can't thank the community enough for the support. Without you guys, these switches wouldn't be possible. Hopefully we can pinpoint the issues at hand to make these the perfect switch going forward!
That being said, after shipping out almost all the Zealios (still working on cables/spring lube), I got really curious if I could replicate the chattering issue in order to experience it first hand.
I spent Saturday afternoon modding/lubing my 65g Zealios (they are unbelievably quiet after lube!) and soldered my Viper on Sunday. I used my Edsyn 951sxe @650F with a medium sized chisel tip and Kester 44 63/37 0.021" solder. It's a 95W iron so heat transfer and regen is really quick. Both pins and joints were touching the tip, and solder was being fed onto the tip to flow. Viper PCB has a larger hole for 1 pin (to support matias switches), so those pads were heated for longer than the other.
Here's the result
I only grabbed 60 Zealios out of the bin and nothing more. I did not replace any switches or do any "checks". No chattering or actuation before bump was found. I wiggled all the keys in all directions before spamming each key a couple times in EK's switch hitter.
I will say that the transparent line of Zealios were designed for enthusiast use only (meaning no automated wave soldering). Yes, the bottom housing has a lower melting point than stock Gateron/Cherry switches, but that's the limitation of the nylon polymer used to achieve the transparent look. Gateron has confirmed with me that it will be fine for hand soldering though. If manufacturers were to use Zealios, their version would require the use of the "milky" nylon bottom housing that has fiberglass mixed into it. Maybe I got super lucky, maybe it's the soldering technique that's deforming the bottom housing. Would anyone be able to perform some more testing to see if non-soldered Zealios are affected?
There was some discussion on reddit found
here and they think it may be the stem size causing issue. It could be both though?