New Problem for me

[dandangerous (Dan Dornback)]

I would also suggest checking the v-wheels on all axes, make sure they are snug. Rotating a wheel should move the assembly (snug but not too tight…). If you can spin a wheel it is too loose. That leads to the axis rocking/lifting/moving when it should be firm.

Router bearings are another one - when I fixed the Z-plus in the post @mhotchin referenced, also discovered my router bearings were toast. This is the rebuild on the Dewalt 611:

Dewalt 611 Bearing Rebuild

Been troubleshooting some cut issues for a while, after fixing and eliminating a lot of other problems (loose v-wheels, stretched belts) finally got down to bearing play on the router. I didn’t measure it, but could grab the collet and feel the physical movement up and down. I’d guess at around 0.005 - 0.008" range based on the cuts I was was seeing, which really showed up in aluminum. So, time for a rebuild! I looked around and could not find comprehensive instructions on what’s needed and how…

Also - depending on your machine (I have the SO3 XXL) - bed deflection. Mine was getting about 1.5 mm of downward deflection in the middle with light pressure. Fixed that here:

SO3 XXL Bed Deflection - Center Support Solution

A while back I noticed considerable deflection in my SO3 XXL bed while cutting aluminum. During the plunge the bed would push down and then slowly raise back as the cut progressed. Did some measurement with my dial gauge and it was about 1.5mm of downward deflection with light pressure. The rails on the SO3 XXL are actually convex, mine had a ~6mm rise at the center. Hard to capture in a pic: [image] Under load, when fully assembled with the weight of the bed, etc., this rise levels out and …

I was seeing a similar thing to you, turned out it wasn’t one thing, rather a combination of multiple small problems amplifying together and translating to bad cuts.