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I had the same problem as many people when pushing the gears into the keychain. On one gear, a tab snapped. The other gear went on, but was too tight to spin. My solution was to redesign the gears with double the tolerance. If you are having trouble like I was, please see my Remix, THINGY # 593803: http://www.thingiverse.com/thing:593803

Gearbox Keychain with Loose Gears
by brx017