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@Sumo
Well I've had this problem before and can't figure it out. I've tried changing where I put the last bit of tyre over the rim too to check I wasn't pinching it and it still happens. I've now snapped 3 tyre levers because 23mm wire bead gatorskins are bastards so have pumped this last one full of Zefal puncture repair stuff and it seems to be holding for now.