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I'm sure the protrusion is there for a good reason, possibly to keep the knuckles from rolling apart during curves.
It does more bad than good in my experience
I've never had a problem. What do you think is the "bad" thing that it is doing to you?People cutting them off because they read on the internet that they should? This is exactly why I don't buy used N scale trains.
One man's explanation, (YouTube), was to make the Kato's play nice with his MTL's. Also on YouTube replacement of RTR Kato couplers on their passenger set with Kato couplers from their Coal Porter set fpr more close coupling.Have not tried this, nor experimented. Shame, nice company, good models, guess this is their weak point. Every company's got one somewhere. Still fixable and not a "decision to buy killer", my opinion.
a draft gear box for body mounting, wide coupler swing and relatively-close coupling
Not really. Passenger cars with 1015 couplers will work on 16 inch radius curves, both with each other, and with Kato and Walthers/Railsmith truck mounts.
Those are pretty much mutually exclusive goals.
It's the close coupling that suffers....GREATLY.
The objective was to make the cars noticeably closer, and not necessarily to prototype dimensions. Even HO scale couldn't get that down. There are two factors: Coupler length and Coupler size. The length is obvious, and there's a give-and-take factor involved in allowing coupler swing. Coupler size is also a factor, as the MTL 1015 coupler knuckle is rather large, and its design creates noticeable slack, which can vary the distance of these cars noticeably. The Kato stock coupler is slightly smaller, as with the MTL TSC and 905, so that's why the latter two were considered as options. In N scale it's quite literally a Game Of Inches (or in this case, millimeters).