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Nub - I've only heard of this referred to as a pin (like the drive pin on a spindle). Is "nub" common usage? When the core doesn't fit the pin, the the easiest way to resolve the issue (besides discarding the core) is to grind down the core rather than filing down the pin. Alternatively, if a film transfer flange is available with either a key or a pin on the hub, that can be used instead of a split reel.
Flange Spinning Off - This can be avoided by considering how the wind orientation relates to the hub threading. If the reel is being rotated in the direction that would tighten the threading, you don't have to worry about the flange separating during rewind/playback.
Split reels should often not be totally flush when tightened. They usually use a brass crush washer or a rubber washer at the base of the hub to prevent over-tightening, but the brass washers often get lost and the rubber washers wear down, so many split reels are easily over-tightened. If the film is kissing on the flange excessively, and especially if the film is pinching between the flanges, the flanges have been over-tightened and need to be loosened. When you have split reels with these issues, you can determine the degree of backwards rotation required to back the outer flange off from the hub (ex., tighten the reel fully and then back it off one rotation). --JesseCrooks (talk) 19:00, 7 May 2020 (PDT)