ChuckS said:
The scale on my Sawstop as well as other tape scales (e.g. miter gauge) are also not identical to any of the tape measures or steel rules in my possession. I suspect I have the same "problem" with my various combination squares/precision squares.
Yes.
But, I'm not going to do everything in my shop with story sticks - it just isn't practical. Even if I could figure out how to set my tablesaw rip fence based on a story stick, would it be any more accurate? Which maybe points to a difference between making a door versus fitting a door. How many of you use marking knives on your story sticks because pencil widths introduce inaccuracies?
Now, for building things, we all do things like plane all the stock to thickness at the same time without moving the planer bed/head, or cutting all the rails and stiles to width without moving the rip fence, etc. , but there are always times when we messed a piece up and have to match. And then the challenge is how well can we reproduce a setting days weeks later?
Luckily, the observation that the smaller a measurement is, the more accurate it needs to be holds true. No-one marks and cuts dovetail pins to match previously cut tails using measurements, but I'll certainly rip a new floating panel to width using my saw's scale.
With DROs on my tablesaw rip fence, planer thickness and drum sander thickness, plus Incra teeth on my tablesaw crosscut sled and miter saw fence all tweaked to be the same as each other at a couple shared values (eg 20.0mm, 125mm, and maybe 290mm), based on a dial caliper and a shared decent manufacturer for rules (I use Shinwa rules mostly), I'm comfortable for many things to measure then cut. When I know my tablesaw rip fence DRO is dial-caliper matched at 20mm and 125mm, then I'm comfortable doing any kind of rip using the DRO, especially if I'm trying to match something I cut a couple weeks ago using that same rip fence (even if re-calibrated since).
If it's critical, like planing new stock thickness to match something previously done, I'll measure at the next to last pass to be sure I'm getting what I should be getting. And, of course, "sneaking up" on a cut is a pretty standard procedure in most shops for precision matching, but even when DROs aren't zero-calibrated or just off on long distances, they are always dead nuts on for the small deltas one would have one the final pass of something like thickness planing.
I remember when Norm Abram got his Biesemeyer fence in season 2 or something and he talked about it on the show. He said something to the effect of "I'll check with the tape measure because we still can't trust the fence." By the next season he had learned to trust the Biesemeyer.
We have a thread on Starrett not keeping up with manufacturing progress. I think not only have CNCs revolutionized how accurate tooling can be made by manufacturers, I think DROs and similar have revolutionized how accurate projects can be made in home or custom shops without always using the more lengthy trial and error procedures of the past. It's really not beyond a small home shop's capabilities to have trusted measuring and cutting devices that match well enough these days.
But, I suspect I'm in the minority on this.