We are new to Gibson assembly and are using the NEB Gibson assembly master mix. Reactions with vector alone (no insert) give no colonies. Adding an inset of 660bp gave 10s of colonies. But a large insert of 1200 and another of 3700 gave nothing. NEB suggested not to gel purify the PCR products being inserted. So we simply spin-purified the PCR reaction. We obtained 6 colonies in that case after plating 80% of the cells (NEB suggests plating 10% of the cells). My impression was Gibson assembly for inserting a single piece of DNA to a vector should be more efficient than this? And why does a gel-purified small insert work but not a gel-purified large insert? Should we be doing something differently or using another source of reagents?

Some details: we do the assembly for 60 min at 50C with 40-50 ng of a 4790bp vector with a 3-5 fold molar excess of each insert. In some cases the insert is slightly diluted (1:1 or 1:2) before adding a microliter to the reaction, in other cases we add undiluted, purified insert (up to 1.5 ul).

Thanks for any advice and sharing your experience.

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