Acceptable vertex mismatch error

[Philippe Hurbain]

I have not yet considered improving the rim (significantly more complex that the tire...).

I don't have access to Edger2 (I use the eeevil Mac platform).

The source code is available and it's a simple C++ console application, so I guess you could compile it on Mac?

Maybe it would help if Edger2 implemented a feature that flagged any two points were >0.01 u

It doesn't do that directly, but it can flag mismatched edges between facets. This either means a T-junction, or unmatched vertices.
I also have another tool (Unificator) that can automatically fuse vertices close enough.