Mine is brand new and I was a bit horrified to see that much play in my plate. My local dealer loaned me his demo ( no play at all) while he tried to sort mine out. He told me over the phone that he had solved the problem ( removed about half of the play) by bending the tabs.That was not really the answer I was looking for. He also suggested that I could shim it in tight with toothpicks if I wanted it to be movement free. Yes I want it to be movement free and no I do not want to have to shim my $800 routers bushing adapter plate with toothpicks.
In most applications I am certain that it does not make any difference if there is a 32nd" of play but for small and intricate inlay work, zero movement seems to be an acceptable expectation.
The gentlemen at Festool tech support seemed to believe that a 32nd" was normal and totally acceptable and that it wouldn't make a difference to the accuracy of the tool. Hmmmmm, again not the answer I was looking for.
Interestingly, when I first showed my dealer the issue he was astounded and said that there should be zero movement in the adapter plate. Two days later, " thats normal heres some toothpicks".