Is it the penny sleeve or the card holder, ie. CS I? If it's the penny sleeve, and I'm probably in the minority here, I forgo that part and just put them directly in a CS I and send it in, especially older cards and one's with just a hint of corner wear. If you insist on using penny sleeves use the 2 3/4 x 3 15/16 sleeves. They're a little larger and easier, more forgiving, than the smaller sleeves.
I am with you trex. Never understood the need for penny sleeve in a card saver. Particularly with the risk of the corners. I hate penny sleeves. I have heard there is someone that sells penny sleeves with a corner cut, but I assume they is still some risk or a corner is bare. What is the point of risking putting in the sleeve to begin with if one of the corners are bare.
I did use penny sleeve for rigid. For some reason, I never liked the cards bare in rigids. I think that had more to do with them moving around and with the sleeve they were tighter.
Have screwed around with them all, but like card savers without sleeve over the other ways. Interested in why others have to have sleeve or absolutely love the rigid holders with sleeves over a card saver?