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maso
I used OpenBuild V-slot too, and for me it was more than a few mm. I was using 10-32 hardware, so that might affect things a bit. But I couldn't even fit the nut and washer in the slot, much less the plastic part too.
I wound up redesigning the t-nuts to fit some small-profile 10-32 nuts. Not the best design, but I superglued each one in and they are pretty sturdy.
Edit: Here's the nuts I designed. In case it proves helpful for anyone.
Hey maso... Did you also encounter the issue that OpenBuilds V Slot is not compatible with the carriage design? I'm finding that there's a fair bit of a gap between the mini V wheels and the extrusion. Along the lines of 3-4mm total (probably about 2mm each side?). Obviously this means there's a lot of play. :(