As with most projects, there has been a huge amount of iteration along the way. The process has been model, print, test, revise, model again, print again, and test again until the parts finally behave the way they need to.
At this point, I’m pretty happy with the tolerances and how everything is fitting together. The mechanical side of the project is starting to feel resolved, so the next step is moving into the coding and testing the actual silkscreen workflow.