I found the actual problem as well as the fix for it
. This way you can keep the spacer in its original position. It should also solve the problem for everyone, not just some. It still involves a little bit of work though. Long story short the PCB slits on the spacer are too far apart for my particular revision (NEO-AES3-6) so the slits on the spacer don't line up with the slits on the AES.
Lower alignment pushes upper row out of place
https://drive.google.com/open?id=1NPaC_ ... dnqWcrczKq
And vice versa
https://drive.google.com/open?id=1NKvrk ... 4H6YyfuTC_
This forces the PCBs to be separated to the point of losing connection with the two middle copper contact rows on the AES. I narrowed things down by removing the shell while retaining the spacer. In this upper position the AES would boot.
https://drive.google.com/open?id=1NDLhZ ... LUffGSOkvk
But when pushing the spacer into the original lower position I had to use quite a lot of force indicating that the slits were not lining up, forcing the PCBs apart. After that the AES wouldn't boot.
https://drive.google.com/open?id=1NJvIV ... IBhnHIbkwt
You can clearly see how the spacer gets bent due to jamming due to trying to force the PCBs apart. And the more you force the spacer down into meant position the more you force the PCBs apart.
https://drive.google.com/open?id=1NUATT ... cM9_E-YYE2
File the slit down towards the middle (so down in picture).
https://drive.google.com/open?id=1NVbYq ... yQbhTXNpVR
File the other slit up towards the middle (so up in picture).
https://drive.google.com/open?id=1NXQ8W ... 7TN-liJfyy
And with modified spacer/filed slits in place.
https://drive.google.com/open?id=1NprGr ... O6vh_o2O7Y
And there it is..
https://drive.google.com/open?id=1NpgCv ... OZ1xtPhNJr
My AES revision: NEO-AES3-6
https://drive.google.com/open?id=1N-n5M ... BDtg-acwMD