you know what Rob, I was thowing tools around last night building the shocks too! lol
after speaking with Cree today its basically problems with burs on the white plastic spacers, atack them with a file/knife and trim them up good, apply lots of slime and they are some how easy! you can even be quite aggressive cutting/filing the white spacers in diameter. (white spacers, not the white snap clip)
Hope that helps, I have super smooth shocks now... well at least for my first go at building AE shocks!