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First, NMSEd thanks for being part of the discussions.

If this question has been answered, sorry, I don't recall seeing it.
Why weren't the holes punched in the same fashion as the picture shown?

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Because the holes were not flared in the 1st generation of the OEM Filter made for Chrysler, the holes were punched with flat edges. Only after the perforating tooling became dull and a burr started to appear on the punch down side was the change to the tooling made, and the flared hole iteration began.

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