I'm trying to insert a 120bp segment into a 4k vector using Gibson Assembly. The purpose is to replace a 27bp portion of the vector with NNKs. The insert is ordered as an ssDNA oligo, and then made double-stranded after annealing to a primer, and completing the second strand with Klenow. It has 36 bp overlap with the vector. The vector backbone is prepared using inverse PCR, because there are no restriction sites around the target area. I then use DpnI to digest the WT vector, and then gel extraction to remove all the DpnI fragments (which can be up to 1kb and tend to ligate back into the vector during Gibson Assembly, so gel extraction is necessary). After cleaning/concentrating the vector product with the Zymo kit, I mix the dsDNA insert with the vector backbone (1:5 vector to insert ratio) with Gibson Assembly, and then chemically transform into homemade MegaX (DH10B) competent cells. The goal is to maximize transformation efficiency, since I'm creating a library.
This has worked for me once, several months ago, using a similar insert that was only 87 bp long (21/18 bp overlaps). Since then, however, it has consistently failed-- I get zero colonies, or at most, a few tiny colonies. I later switched to a larger insert (120bp) since some said that the T5 exonuclease of Gibson Assembly could totally chew up a small fragment. Still, no luck! I can transform the original vector template successfully each time, proving that the vector, antibiotic resistance, transformation protocol, and cells are all good. I've also run a positive control with my Gibson mix, which has worked.
I get colonies if I skip the gel extraction step, but then half of the colonies contain weird combinations of the insert and DpnI fragments that were not removed, so that's not desirable.
Any other thoughts for troubleshooting? I can't understand why this worked over several repeats in the past, and suddenly cannot work anymore. Thank you!