It is possible the pommel could be causing the SD card to 'pop out'. I don't really rememebr if any of the CFs were mounted so that the SD card was outside the recharge port plastic holder. I do know I had one or two sabers that when I got them back from the installer, the SD card was loose and had to be re-inserted. I just assumed they had possible 'popped out' during the shipping.
In the early designs of the saber, and up through machining, the recharge port was just going to sit loose in the pommel on a wire whip. There was no room for the recharge port in the saber because the CF, wiring and Li-ion PCB were taking up all the space in the pommel neck. It wasn't until after all the saber had been shipped to the installers and one of the installers found that you could actually fit the Li-ion PCB up with the batteries that I had enough room to play with in the pommel neck to design the new ring setup. Yes, that means I did not have the sabers in my hands anymore when I designed and machined those recharge port holders. I shipped them out as quickly as possible to the installers so they could continue their work.
As far as needing to remove an SD card to charge the saber - that is a new one to me. My saber has just enough room to fit the larger diameter of the recharge jack in the port without hitting the SD card. I did not charge any of the other saber so I did not realize any of them had a clearance issue. But, it must be expected with a saber as tightly crammed as this Obi, that some trade-offs in ease of accessibility/use must be made to have a saber with such accuracy and hidden features. If anyone is having issues with their saber and are not happy, let me know and I will see what can be done to help. I can't promise I can solve every problem. This saber is rather unique in how cramped it is and how it operates - some problems just have to be lived with, others can have solutions (there is one issue some users are having that I will address later today in a new post).