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@benbrangwyn
Who breaks and reassembles the chain on the bike? You? Do you really know how to do this?
It's easy to damage a chain when removing a rear wheel and letting it drop out of the dropouts and swing downwards, torqueing the chain nastily.
If the chain has "magic links" (ie you can join the chain without using any tools), then that's usually a weak point in the chain.
KMC are a reputable brand of chain, so mebbe you'll fare better now.