Hi Dwayne,
This may be one of those rare times in history where it was NOT the male's fault! In this rare historical case, the fault lies with the female half. I know that most men will jump to the conclusion that the male part is too big, causing the overly "tight" fit. Alas, this is not the case here, it is that the female part is too small.
After using hundreds of batteries with deans connectors over the past 20 years of flying electric models, I found that sometimes the female side was too tight due to minor problems with the molded interior of the plug. If you look very closely, using a strong magnifier, you will see that there are distortions of the interior walls and/or extra flashing material on the opening edge of the plug, usually in the corners.
The vast majority of problem plugs can be easily corrected with a few minutes of trimming with a sharp Exacto blade and a good magnifier. I have found that a head strapon magnifying google is a big help with this repair. You can also use the magnifying app on your iPhone, with the light feature to make the job even easier. If you are very careful, you can use your Dremel tool to do this task faster, but this may be like using a sledgehammer to pound in a small finishing nail, fraught with danger?
Since this is a "safety" plug, please don't stick any metal device into the female opening without first ensuring that there are NO batteries connected to this female part!
I hope this helps solve your "tight" plug problem.
Regards,
Rudy Taube
AMA 1667