• The hole for the headphone socket on the outer shell doesn’t provide enough clearance for the plug footprint of my headphones..  This can be easily remedied with a Dremel and a 953 Aluminium Oxide grinding stone on a low speed so it wouldn’t melt the plastic.
• The inner shell has a deformity right underneath the docking connector (green arrow in photo) so it kinda lifts up a little around that point letting dust in. Sigh.  Since I’ve lost the receipt, and everytime I’ve been in Optus they only have gay colours in stock to replace it with, well I just gotta live with it – life’s too short I guess

Finally…

• The bridge of the inner connector (red arrow) that sits above the dock connector has started scratching the metal band on the iPhone. I’m not sure why but I presume dust gets in and rubs against the metal – scratching up the iPhone which is why I bought the case in the case in the first place!

The way I fixed it was…PVA glue.  PVA is safe, dries translucent, and is easy to remove (you just rub it off with your finger) and is pretty easy to apply.  In the garage, from other projects, I had a bottle of PVA from Bunnings and the smallest paintbrush I could find (1/8″) which is about the same width as a nailpolish brush. Just brush a layer or two of that shit onto the metal band of your iPhone – you could go the whole way around, or do what I did and just do the bottom side since it was the only part being scratched up.   Be careful not to get PVA into the seam between the band and the glass, I think it will be hard to remove.

Give it 10 minutes to dry, touch test it and whack that case back on!  Job done, back to drinking beer.