I have recently became interested in a routine by Roger Klause called New Sponge and Sleeve. This routine involves putting and removing a sponge ball
several times from a TT. I am using a standard size thumb tip and a 1.5 inch Goshman Super Soft ball. Problem I am having is once I get the ball in the TT
it is very difficult to remove. If I keep the ball between the thumb and side of the tip, then everything barely fits, or sometimes part of the ball is seen
hanging just outside the TT.

Any thoughts or ideas would be greatly appreciated.

Walking Bob in Iowa

Because thumbs vary so much this is something I think you have to work out for yourself. Plastic thumb tips can be resized with hot water.

What you need is a magic tt that turns inside out into a sponge ball.
if not then, cut the opening of the tt down, put a little slit on the bottom inner side, so you can grab the sponge ball better.

or else invent a TT with a hinge on it, that immediately releases its load and recloses eheh.

Can a sanada gimmick be substituted for the tt?

W a sanada, you would have to reappear the ball from somewhere other than in their sleeve. So a TT would be the ideal choice. unless someone has a better idea

I can see where the very old "Elusion Vanish" for a silk can be employed with sponge balls. (Burling Hull)

In this way, a small ball easily inserted and removed from the TT can mask the production and vanish of a much larger ball, or many balls.

To clarify. The left hand apparently produces a ball from somewhere with only a small portion seen at the fingertips.
The right hand reaches over and "takes" the ball to rest large on the right palm in display as the left hand is casually shown empty.
The large ball is apparently dropped into a basket while the large ball is compressed/palmed.
Then the process is repeated as desired.

or, the large a ball is apparently placed in the left hand with a part still visible. With attention on the left fingers the large/palmed ball is ditched.
Then the ball is vanished in a very visual way - the solitary left fist closes and reopens with nothing.

Obviously, the compression feature of the balls should never be revealed/exposed

That sounds like a great idea! But could you close your fingertips far enough to handle the spongeball naturally? I've never owned an SG.

Check out Steve Valentine's Castle Lecture DVD. He has a great handling for the sponge ball and TT routine involving two vanishes and two appearances. That routine alone makes the DVD worth it and all the other material is killer as well. Highly recommended if you're a fan of Klause's routine.

Cut a small triangle on the bottom side of the thumb tip, only about 3/4” or 1” and that will give you the ability to pull It out of the thumb tip and still use it. But it will essentially make your thumb tip only be good for sponges.

This is only good with a vinyl thumb tip.

Another option is to try different diameters of tips. From what I remember, Bob Little, as well as Daytona Magic, carry a variety in sizes. I used a standard Vernet, but it took a great deal of work to master the Klause routine.

Hollow out the sponge ball to make it easier to collapse inside the TT, and then make sure it collapses along the rear edge of the TT (even with a tiny bit of it sticking out over the edge) so you can pull it back out.