Quoted from eyeamred2u:I would have lowered the switch arm first before sanding and from the video it appears the plunger hits the ball too low. I would bend the bracket to raise the coil angle
Oh Believe me, I Thought it was plunger alignment as well. I adjusted the alignment up and down, side to side and the problem never went away. If you watch closely the ball launches at the end of the playfield switch cutout not before.
After all my changes to the alignment it never got better. I thought about moving the switch and changing the timing on when the ball was hit.
The strange part was the ball was only launching in the air about 65% of the time. It was not happening every time. That is what lead me to believe it was not the alignment. I discovered this was because if the ball went back up the lane and did not line up with the playfield switch cutout it would not launch into the air since it would miss the bump at the end of the cutout.
By slightly sanding the end of the playfield cutout to create a more gradual rise so the ball no longer jumps up.
This is why I posted this unusual issue. It took me a while to diagnose and thought others would benefit from knowing about this.
If there was not a Kickback in this lane this bump would not be an issue since the ball would never be shot back hitting the cutout bump.
It was not the playfield. It was from the clear coat buildup around the cutout. When you spray clear on a playfield it tends to "build" and gather around openings. This is what happened here. As soon as that "extra" clear coat was removed, so was the ball launch problem.
After sanding the bump just ever so slightly I have not had one air ball. The problem was the clear coat bump.