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I've done everything in PETG, but my setup seems to have a very great deal of holes being undersized if they are facing down.

Yep, threads are all 0.1mm layer height and I've got them butter smooth yet without wobble, correctly pulling the inner assembly back Really happy with them.
Now getting the X-axis assembly onto the final verification stage - I'll try the same trick there too to see if I can make the slidey thing slide in.
Hopefully, I can get a CARL style printer setup right on the first assembly, without needing to go back and improvise a functional temporary hybrid to reprint something.