I have been using Gibson Assembly to insert a 7kB fragment into an 8kB linearized vector. After assembly many colonies form, but colony PCR on the transformation consistently shows a 1.5 kB product instead of our expected 7 kB. RE digest of the plasmid shows a single band at ~10kB. There were no off target bands of the PCR fragment which contains 25bp of overlap with the vector and GC content of ~60%. The vector was dephosphorylated during digestion to prevent re-ligation.
What might this insert be?
I am using a stable E.Coli strain, but could recombination explain this?