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I believe the calibration issue we're seeing with the x/y is in the machine code processor. Things can also get a little messed up if there is debris in the rack and pinion drives. Just haven't had an opportunity to tease it out yet.
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We do have a reamer, but have had mixed results when using it on oblong holes. Using a micrometer on a sample after under-sizing still shows a
position margin of error of around +/- 0.001 in a dimension.
In any event, since the gears arrive tomorrow we'll likely just make the gearbox and report back in November. If we see signs of premature wear during our planned 50-climb test, we'll probably get steel gears and just brute force it. It's in an easy-to-replace spot and we're building a spare as it is.