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1.- I recently printed one of these on my Taz 5 at .2mm and everything came out pretty well. I would recommend the finest layer height that you can consistently avoid "spaghetting" at, as to preserve the structural integrity of the two tabs in the actual separation end of the piece.
2.- Yep. I'd personally recommend printing it with the axle (lego) side facing down, with supports, as that can help to keep the tabs from getting messed up.
Thanks for the make btw. Really appreciate it!