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Anyone with hands on experience with fine tolerance machining will know that inserting a 1.250 dia shaft into a 1.252 dia hole is only simple in theory.
I think the most probable reason for focusers to be a little sloppy is so that EPs can be changed in the dark, in the cold, with relative ease. If EP barrels were machined with a 1/4" leadin land say about 1.245dia, then a close tolerance betwixt EP and focuser would be no problem; but they are not, and there are far too many in the field to ignore by not allowing the fact. Also a 1/4" leadin land would likely make the barrel too long for some applications, so I guess we just have to live with taking up the slack with a lock screw.
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