It still was not smooth enough when I tried to spin the gear on the cross axle. So I got out my Dremel and tried to smooth down the edges manually. It is not perfect, and I remember why I was using pins instead of trying to line items up by hand/eye. I am not sure it is as straight as the original.
I went ahead and put the clock back together and hung it back on the wall.
There was a little bit of crazing since I didn’t anneal the acrylic, but I don’t think it looks bad.
I don’t think the drive gear adhered well. I was looking at it last night and I think it is loose already.
I will probably need to work on the drive axle again, but for now I am just glad to have it back on the wall and running again!