Need some help with nested instances

Any help is appreciated. I am trying to get rid of my nested instances
in a component but I can not figure it out. I have already tried solidsolver and cleanup3 it did most of the work but will not get rid of nested instances for me. I’m not sure what else I can try or how to get rid of them. I have attached the model in this thread.

Thank you all in advance.

gearmodel.skp (1.8 MB)

Your model is not a solid so you will have to go in and clean up all those seams.

Your model has lots of issues, it took me longer to make it a solid that it would take to draw.
Your main problems are that you have 2 groups inside another group with some loose geometry.
But within those groups you have used a variety of segments for your circles, one of them having 512 segments, more than 1 per degree, serious overkill, but more importantly they don’t line up, which is what @liamk887 is showing you.
You also have internal and reversed faces.
All these issue add up to a model that needs a lot of work to be a solid.

By the way, nested instances just means that you have a group/component within a group/component.
A solid can only be one level deep, so raw geometry wrapped as a group or component.

I had a working model but the measurements where off a mm and then I accidently lost that file so I had to do it all over again. I haven’t got a clue how I managed it in that file so I’ll keep on trying some different setups.

Here’s a quick demo of one method of making your object as a solid. Obviously I haven’t bothered with the detail of the teeth, the number of segments or the accurate sizes. But the process would be the same.
Gear

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