Quote Originally Posted by curious aardvark View Post
you're asking the wrong people :-)

You should ask the print service who are printing the part for you - they will know what tolearances their printer can produce.

But logically if 0.2 is too large then reduce it :-)

But ask the people printing it first :-)
The people printing recommended 0.1mm gap in the part sizes. This makes a 0.2 difference in diameter (i.e. 0.1 x2) which, once one has done some light sanding does seems to be too much in practice. I next time I shall half the gap.

Either way I'm still not sure what to do about finishing with paint / lacquer etc. I have bought some automobile wheel paint and some lacquer to experiment with. My plan is to build it up with a layer of this stuff and then sand down the mating surface of the male part, in a controlled manner with fine sandpaper.

I have also bought some more sand papers so that I can cut it to size and wrap around the male part and sand in a slightly more controlled manner. Watch this space