A slight update, I'm running into a design hiccup of trying to get a thick enough arm using bolts of reasonable length (i.e. not 150mm long) and have considered two options. Either splitting the gear in half, which will allow me to nest some parts to make the assembly more compact, or print upright. I've been avoiding these two outcomes because the first one introduces more opportunities for misalignment when the gear arm is in two pieces, and the second results in teeth that have a stepped surface rather than a smooth contour. I thought the stepped surface on the gears contributed to the original gus's inaccuracy but now I'm not sure.

Any thoughts on the viability?