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has any one actually told why this has happened?

it's usually because your machine has taken off a little too much, if one looks down the top side of the key after cutting, one should see a small line all the way to the nose of the key (uncut), if the cuts meet then the key 'jams' in ignition.

i try to look at each key to assertain this before customer tries in ignition - saves all the bother!

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