Hi tdelara

You have a Straight Adjust on the connector you are using, that is causing it to fail.  The Straight Adjust was only designed to be used when jobs came in from CADduct or CADmep without an extension on a Throat, over the years people just started using it to make connectors when it is not needed.

If you have .5 turnover and .5straight it is just going to add 1" on the end, so just make it a 1" Turnover and get rid of the Straight Adjust.

Dave Dykes