Cool presentation Snake... Love all the interesting/diverse way you integrate parts together.
Nice move in highlighting Mathias's woodger program... I bought it a few years ago and it has served me well in many diversified jigs... haven't graduated to incorporating into puzzles... yet. Having a cutting laser certainly makes integrating the gears much simpler (for me in construction).
If your first cut is too short... Take the second cut from the longer end... LBD