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I was unable to build the latest shipped ErgoDox over the weekend due to the stabilizers binding. The little inserts that attach to the keycap appear to be jammed very firmly against the side of the clip. I can't tell if the spring is pushing them too far back, the clip alignment on the plate is off, the whole stabilizer is misaligned with the switch or what.
This is with the 65g Zealios, what switches are other people using when they're seeing this stabilizer issue? I built two ErgoDox from the first drop, one with Cherry browns and the other with Matias tactile and didn't experience any stabilizer issues.
I have the 78g Zealios and had this issue on one stabilizer. I solved it by desoldering that switch and bending the plastic holder for the stabilizer outwards, reinstalling it, pushing the switch over to one side to get more clearance, then soldering it. It seems to have resolved the binding, though a bit of lubricant might smooth it out some as well. You might also try replacing the switch with one of the spares to see if that helps any.
Did you follow the instructions about installing the stabilized switches first and testing those before doing the rest? I didn't, but I guess I got lucky with only one sticky switch. Might be the whole board is shifted just so and the switches aren't quite aligning as they should.
I built my infinity ergodox from the first drop with 65g zealios recently and I found that if I installed the stabilizer moving plastic pieces one way, it would bind, and I flipped it around the other way and no problem. Maybe I had it the wrong orientation the first time. but maybe that's your problem?
I built mine with cherry clears. The left side stabs work just fine, but both keys with stabs on the right half bind terribly and get stuck. I ended up removing them all.