Can anyone help with why my PCR worked one day and not the next?

I am attempting to PCR amplify my empty vector backbone ahead of Gibson Assembly and am using one backbone with two sets of primers. I ran small test PCRs (20ul) under various conditions for optimisation (Gel 1- test) using Phusion Pol and the NEB-suggested annealing temp and Tm. The conditions shown in lane 1 and 2 worked beautifully and show amplification and slight weight change from the input ev (lane "In") as expected.

The DNA template was kept at 4oC for a couple of days before I then repeated the PCR at a larger scale (50ul) to make enough template for my Gibsons. I used exactly the same conditions, DNA template, buffers, dNTP, polymerase alliquot etc with fresh sterile pure water, and even used the same saved PCR programme on the same thermocycler. And I just got smears! (Gel #2, lanes 1/2). I have since used fresh alliquots of everything, including re-dilution my template DNA and primer stocks in case there was something in the water, but I still consistently get smears.

Can anyone help troubleshoot why my results have changed from Gel 1 to Gel 2?

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