Screwdriver
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Can you scale XYZ axis independently in your slicer ? A bit of a long winded way of doing it but it may help with the 4mm thickness becoming 2mm, scale Z = 200% or whatever notation the slicer uses.
Yes that was the easiest way to bulk it out without having to remake all the gears. Did a bit more to it and sorted out the clearance issues. It should now almost be robust enough to hand over to a six year old - once I add a bit of colour!