These are the same types of issues I've encountered when printing various submini cassettes. The tolerances are so tight that extensive 'finishing' or tweaks to the model geometry are generally required.
That said, anything that will get a Viscawide shooting again is a good thing so congrats on the print. 16mm cameras have way too much character with modern films to be languishing in a box due to lack of cassettes.
If you have a knack for modeling you could convert the design to one using a dedicated feed & take-up cassettes. The feed side doesn't need a spindle at all and the take-up only needs the spindle exposed on one side. Simplifies printing and probably helps with light-tightness.
Edit: eliminating the spool on the feed side could theoretically lead to film flatness problems due to less tension but who knows.
You name it...Now, to find a working Viscawide...
Well, there are more than a dozen of them listed on EBAY right now, and if you have any success with these -- and want to make some money -- I can list your details on the SUBCLUB.
With the exception of one Viscawide in non-operating condition in Canada on Ebay, I only see cameras starting around $150 USD + shipping and up from Canada, Austria and Japan.
That's a bit expensive in my opinion, but depends on your "want" factor. If you pay that much, it should be in immaculate condition with magazines included at a minimum.
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