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sorry for the slow response.....

I have used a 0.25mm nozzle in the past for some detailed models, but have never tried a 0.6mm nozzle. All of my work on the rewinder has been with the normal 0.4mm nozzle that came with the printer.

The gear pictures you posted from the 0.6mm nozzle are indeed ugly. I am not surprised that things did not fit or run well after seeing those.

The gear tooth profile came from a program called gearotic. I think most people use this software for machining or laser cutting. I simplified the profiles a bit for 3D printing and did have a 0.4mm nozzle in mind when I did it since that size seems to be the most common.

For layer height, I get good results when everything is printed at 0.3mm. The only places that 0.2mm (or 0.15mm) improves the print are: teeth on the track, gear bearing hole in the stand, and the two PTFE arm mounting location in the stand. Thinner layers also eliminates any chance of stray filaments in the threads of the cap and nut. But, that is a pretty rare problem that very few people encounter.

I played with the variable layer height settings in PrusaSlicer to optimize only the areas listed above. Unfortunately, all object on the plate must use the same layer size with variable layers which caused the print time to increase dramatically. As a compromise, my gcode prints the track at 0.2mm (even though only the teeth really need it) and everything else at 0.3mm (leaving some chance that vertical radii on the stand may need cleanup).

BTW, FlamenG updated the spring track this morning, so feel free to grab the new version if desired.