How should we handle the disappearing edge line?

There is something wrong with the condlines between axlehol8 and axleend2 in one of the 4 "grooves".
- "How should we handle the disappearing edge line?" I think it looks better with an edge line instead of a condline in the grooves of axlehol8

I think the outer ends of the bevel should be full edgelines instead of condlines to form some kind of chamfer (two rings, base and the one above)

One inner corner was off by .0402

Since we are trying to get closer to the real thing, I would make it 0.5 ldu shorter to account for the physical axles being 1 ldu shorter than their target size. This doesn't prevent the connectivity to be made to fit ideal bounding box, preventing off grid position.
Like this:
2 24 1.8579 .5 1.8579 2.6902 .5 1.5221
2 24 4.8067 1.08584 1.5822 5.6023 2.5 2
2 24 2.6902 .5 1.5221 4.8067 1.08584 1.5822
2 24 1.5221 .5 2.6902 1.8579 .5 1.8579
2 24 2 2.5 5.6023 1.5822 1.08584 4.8067
2 24 1.5822 1.08584 4.8067 1.5221 .5 2.6902
2 24 1.8579 .5 -1.8579 1.5221 .5 -2.6902
2 24 1.5822 1.08584 -4.8067 2 2.5 -5.6023
2 24 1.5221 .5 -2.6902 1.5822 1.08584 -4.8067
2 24 2.6902 .5 -1.5221 1.8579 .5 -1.8579
2 24 5.6023 2.5 -2 4.8067 1.08584 -1.5822
2 24 4.8067 1.08584 -1.5822 2.6902 .5 -1.5221
2 24 -1.8579 .5 -1.8579 -2.6902 .5 -1.5221
2 24 -4.8067 1.08584 -1.5822 -5.6023 2.5 -2
2 24 -2.6902 .5 -1.5221 -4.8067 1.08584 -1.5822
2 24 -1.5221 .5 -2.6902 -1.8579 .5 -1.8579
2 24 -2 2.5 -5.6023 -1.5822 1.08584 -4.8067
2 24 -1.5822 1.08584 -4.8067 -1.5221 .5 -2.6902
2 24 -1.8579 .5 1.8579 -1.5221 .5 2.6902
2 24 -1.5822 1.08584 4.8067 -2 2.5 5.6023
2 24 -1.5221 .5 2.6902 -1.5822 1.08584 4.8067
2 24 -2.6902 .5 1.5221 -1.8579 .5 1.8579
2 24 -5.6023 2.5 2 -4.8067 1.08584 1.5822
2 24 -4.8067 1.08584 1.5822 -2.6902 .5 1.5221

I'm not sure about this origin. But it make each axle that little bit shorter.
Do we really want that?

And I really don't want a loose edge prim on the top surface. The variation in design, and over time, makes it unnecessary.
Keep it simple.

I meant manually converting some conds to lines, especially these:
2 24 5.1213 1.0858 0 4.8067 1.0858 -1.5822
2 24 -1.5822 1.0858 4.8067 0 1.0858 5.1213
2 24 -4.8067 1.0858 -1.5822 -5.1213 1.0858 0
2 24 0 1.0858 -5.1213 -1.5822 1.0858 -4.8067
2 24 4.8067 1.0858 1.5822 5.1213 1.0858 0
2 24 1.5822 1.0858 -4.8067 0 1.0858 -5.1213
2 24 -5.1213 1.0858 0 -4.8067 1.0858 1.5822
2 24 0 1.0858 5.1213 1.5822 1.0858 4.8067
maybe more, like the ones at the base:
2 24 -6 2.5 0 -5.6023 2.5 2
2 24 0 2.5 6 2 2.5 5.6023
2 24 0 2.5 6 -2 2.5 5.6023
2 24 6 2.5 0 5.6023 2.5 2
2 24 0 2.5 -6 -2 2.5 -5.6023
2 24 6 2.5 0 5.6023 2.5 -2
2 24 -6 2.5 0 -5.6023 2.5 -2
2 24 0 2.5 -6 2 2.5 -5.6023
this improves the visibility of the corners

The curvature is too sharp on the axle side of the part.
5 24 6 2.5 0 5.6023 2.5 2 5.1213 1.0858 0 6 3.5 0

The central plus shape should be larger.

Closer to 1 16 4 2.5 0 2 0 0 0 0 -2 0 1 0 1-4edge.dat

Tweaked a little bit closer to the suggested line. Don't want to add more vertices.