OK, here’s another question; Why am I seeing results like this; Large fill pattern that seemingly is pushing beyond the parameters in the larger gear housing?
Slic3r has some nasty known bugs at the moment, you found one of them…
You have some possibilities to work around this one:
.) Try to disable the detect thin wall feature (in Layers and perimeters)
.) Try to change the line widths (in advanced), or if you have set them to 0 (=automatic) fix them all to about 1.2*nozzle diameter. Try to lower the values a little bit to increase the gap between perimeters for infill.
.) Try to set the perimeters count to 1.
If you can’t get a good result in the preview, choose Cura for this special case. I’m also using Slic3r, but due to some bugs I also have to use Cura in special situations.
I hope alexrj is back to his Slic3r project in near future!
I just tried slicing the default 5 gear bearing with my slic3r profile on the latest slic3r engine, and it shows up fine under my older copy of repetier host. Maybe its a graphics glitch?