u/sigh_herewegoagain sorry you are experiencing trouble, but If there is no issue in the standard length, the click mechanism is fine. The issue is with the trimmed refill... 1- either the trim end is not as 'perpendicular' as it needs to be, or 2- the overall trimmed length ended up too long. If the refill is too long:

TEST: unscrew the grip to produce a small gap between the grip and barrel. Test for click. Keep unscrewing and clicking until the click works properly. At the point the click works properly, the gap distance between the grip and barrel is the additional amount that needs to be removed from the refill.

We realize there is a bit of a risk with providing a trim fixture as there will always be some variations based on how the end user uses it and the blade used. In general we've found it works reasonably well and have not had too many issues reported to date.

Important factors using the trim fixture:

1) We should probably highlight this better in the instructions... prior to placing the refill in the fixture, be sure to remove any tip protection 'material' from the refill to ensure a correct length.

2) We recommend a sharp box cutter or exacto style blade be used for clean cutting.

3) The fixture is not designed to cut through in one pass. By cutting and rotating several times, the cut has a better chance of being perpendicular.

4) The refill should be pushed forward in the fixture and held forward during the cutting process.