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I'm an idiot, i have just realised what the problem is as i have seen it many times before.

 

There is a raised groove inside the lock down the bottom that guides the keyblank in and keeps it straight, if forced they break off allowing the blank to push off to the side rather than staying straight.

 

Only had it on L&F locks that use the LF2 blank so i reckon the issue is the lock rather than the blank.

 

If you remove the plug and put the key in you can lift the wafers out of one side just by applying pressure to the key head.

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