That is a nifty gadget. I like it. I think your issue is tolerances. You want the holes just a tiny bit over sized. If there isn't any tolerance, say like .003-.005 over sized, it will never work correctly. It will be to tight and not go together. I had to go though all of that in school a lifetime ago. Just my thoughts, but if you waller out the holes just a little bit, I bet you dinner it will go together just fine.