I definitely want to try to pep the cog piece of that. It would be 2.25" in diameter cogs included. The cogs stick out 1/8" from the main body. The beveled inside edge should be 1/8" thick and slope down less than that, smaller than a 45 degree angle. The center hole should be exactly 1.5" and the cog is 1/4-3/8" tall. (this is all scaled to how Glitch looks on Bob's arm compared to mine, and I'm just about his build. Plus, all the dimensions turned out at perfect 1/8ths as I was comparing them in the photo, so I figure it's gotta be right.
The body is 1.75" wide and 3 inches long. The bevel is 45 degrees and the face is 1/8" wide, making the beveled edge come in from the sides 1/16". Then it's 1/2 tall. The 5/8" bar sits higher than the body. The bar end of the body should be flat, the bar isn't set into it. The corners here are not beveled, but the top edge is.
And the bar is 5/8" diameter, 2" long, with a 1" orange section in the middle. It's set a bit higher on the body so that the bottom of the bar is level with the bottom of the body and the top of the bar comes up higher than the top of the body. The edge of the cog then lines up with the top edge of the body and doesn't touch the bar. I can't wait to see what you come up with! Looking again at your model it looks like you got it just about right as is.
I've decided not to use the dremel any more today because everything that could go wrong today has, and I'm afraid I might just put out an eye if I take any more risks.