We have seen on both forums where people have had issues with the Kit front casters going into the caster mounts are super tight. I found it first hand tonight when I broke a caster mount. Talking with Scott about it and we found that the new casters, the plate is just a touch thicker. MakeGood team is working on it and we will have an official fix out Monday!
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I just finished a chair using the Kit. My 1st with a Kit. The front casters were very tight, but I was able to get them in without breaking anything by using a trigger clamp and going slow.
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Yeah I am working on assembly for 3 chairs right now, So far I was able to get them in on one chair, and 1 on a second chair, but broke the other one. Decided to annoy Scott before I went on breaking other parts.
I also had the front caster just BARELY touch the wing once installed. So now I feel bad for telling people that problem was fixed already 
I don’t know if you saw my pics on the front caster. I used the new caster mount with the new TMT files and the caster from Amazon. I don’t think I could slip a piece of paper between the wheel and the wing…lol… But I have tested the TMT with my 62 lb daughter and they spin so I’m OK with them, but a fix would be greatly appreciated.
Thanks
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I used a little Vaseline to help make it go
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I measured the plate on the caster at 1.72mm and the caster mount in CAD reads 1.65mm. Not sure where you had room for Vaseline to fit 
But everyone’s printers are going to be a slightly different tolerance and these caster plates might not be very consistent as well.
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The interference fit was a bit less hard to seat in with mallet.
I didn’t think it was an issue but wow that’s close
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Yeah. With the amazon casters and the ones in the first kits I was able to push them in by hand most of the way and then finish off with a mallet. These… Good luck I had to beat on these harder than I ever have before, and one ended up breaking the PETG mount. That’s when I started asking questions lol.
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You guys already got the casters? I’m sitting here with “label printed” for the last several days.
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I had fitment issue on kit chair I just finished. Thought about swapping in the extra set of Amazon swivels in place of the kit versions but they were about 1.5mm different in height.
The best solution I found for pushing the casters in once already installed (pinned and locked) was to get a screwdriver between the caster plate and the wing side, then squeeze the caster mount with a clamp. There is enough play in the lock pin to get the screwdriver in and this seemed like the least aggressive means of pursuasion.
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Puting the caster mount into the wing wasn’t the problem for these. It was the actual caster into the caster mount. The plate on the new ones are just a little too thick for the slot in the caster mount.
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That’s what I was referring to, pushing the caster plate further into the caster mount once the mount is already locked in the wing. I only had about 300 degrees of rotation before this.
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Ahh ok I follow you now. We were talking about 2 different things. Here is what I was talking about…
Hard to tell from that pic but it split the top out of the caster mount print because it was too thick to slide in the slot. They are supposed to be snug, but this was very aggressive lol.
It seems all related, caster plates have to much interference. I tapped mine with a mallet then small hammer but it’s hard to get them past flush. Didn’t know till after putting the mounts on that the casters need to be 2-3mm past flush.
Ahhhhh. 
That I didn’t figure out. I think I’m going to print those tomorrow and see if they go further than flush. If they do that would fix one issue.
I took a file to even my Amazon front casters to clean them up.
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Just got my kits in this morning and I encountered this problem as well. What is the consensus how to approach it? Tap in with mallet and lubricant? File redesign? Am I allowed to pull the the opening back a fraction in CAD?
Is there an official fix?
Were you able to measure with calipers to confirm there is a difference?
I would think you could file/sand down the caster top plate and keep on moving.
Although I just built a kit last weekend and while it was tight, I got it in without issue or breakage.
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I’m getting 1.7-1.8mm for the plates. I’d rather just edit the CAD file in fusion and re-print if that’s allowed. It takes 2 mins to pull the surface back a smidge.
Unofficially!!!
Here is one that I modified and has been working for me. Still waiting to hear back about an official fix
Official fix this weekend!
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Ahh, you pulled back from the thinner plate. I decided to go the opposite way and pull back from the thicker side.
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