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@RichardC
Thanks very much for that, I think I'll have a go at chamfering the 12T sprocket (I've given up trying to use an 11T one for the reasons you outlined above), as I have some dremel tools that should work OK. But I also thought I'd have a go at milling the side of the circlip (using an angle grinder), making it slightly towards a D in cross-section. But should I install it on the wheel with the flat section facing outwards, or inwards towards the 12T sprocket - or does it not matter which way it goes in?
Thanks in advance.