Finished around half of the assembly. I assembled some of the parts in onshape and realized there’s a few intersections and some of the spacings were off so I changed those. I didn’t run into much problems, but I had a few better ideas that I’ll try implementing in the future:

• It turns out I was being stupid and you need two separate dog clutches for each side. This might actually be better because since they just have to rotate differently but the spacing between them is constant, I can make that outer ring much thicker. This gives me space to bearing sandwich the cam instead of doing some other cooked stuff. However this also means you need two separate shafts which are cantilevered. I need to figure out a way to support the shafts from the inner end.
• While I was assembling, I realized I had done the linear cam (for the gear shifting) wrong because everything can be one part. This will make the entire thing thinner.
• I had a stroke of genius and realized that instead of using that fifth bottom gear which makes everything bigger and ugly, I can gear the perpendicular cam (for the dog clutches) to the gear shifting mechanism, making the entire gearbox so much cleaner. This is kinda cooked because it means the gears will be sliding on each other and because it relies on the tolerancing of 3d printed parts which I don’t trust too much. But if it means making the gearbox look much better, it may be worth it (aesthetics are the most important consideration when designing functional parts).
• I realized I could switch everything from mod 1.25mm to mod 1 or even mod 0.8 because there’s no more cooked gear meshing/unmeshing. However, it may be too late to do this for the V2, so I’ll probably save it for a V3.

The gearbox is not only thinner than the V1, but is also much less cooked. And (probably best of all) the packaging will be really really clean. It does take up more space radially, but that can easily be fixed by switching from mod 1.25 to mod 0.8.