In this episode, Brian and Greg talk about how they set up their tools in their shop and how important it is to set up tools accurately. They then share a few tips on tool setup.

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In this episode of The Maker’s Quest Podcast, hosts Brian Benham and Greg Porter explore how millwright techniques—precision alignment, trueness, and flatness—can be applied to home workshops. While most of us don’t work in factories, many woodworking and metalworking tasks benefit from the same attention to accuracy that millwrights use when setting up industrial machinery.

Greg explains that millwrights are responsible for installing and aligning machinery in factories, ensuring that conveyor belts, worktables, and other equipment are perfectly level, square, and true. This precision ensures repetitive tasks are performed accurately over time.

In woodworking, similar principles apply—especially when setting up tools like table saws, jointers, and bandsaws. While we may not need industrial-level precision, small adjustments can significantly impact the quality of our work.

For many woodworkers, the table saw is the centerpiece of the shop. Brian and Greg discuss the importance of aligning key components:

Miter Slots to Blade: Brian uses a dial indicator (or even a combination square and single-tooth method) to ensure the blade runs parallel to the miter slots.

Fence Alignment: A common debate is whether the fence should be perfectly parallel to the blade or slightly toed out to prevent kickback. Brian prefers perfect alignment for precision joinery, while Greg notes that modern riving knives reduce kickback risk.

Outfeed Table Leveling: While the table saw itself doesn’t need to be level, the outfeed table should be coplanar to prevent workpiece tipping during cuts.

Greg shares his experience setting up his SawStop table saw, praising its out-of-the-box accuracy but ultimately replacing the factory extension wing with a custom torsion-box router table for better precision.

Both hosts agree that bandsaws are among the most frustrating tools to keep dialed in. Heat expansion in the blade, tension changes, and wheel alignment all contribute to inconsistency.

Blade Drift: Even after careful setup, bandsaws can drift due to heat and tension changes.

Wider Blades Stay Truer Longer: Greg notes that resawing with a wide blade holds alignment better than narrow blades used for curves.

Jointer Setup: Ensuring infeed and outfeed tables are coplanar is critical. Greg recommends using a precision straightedge and feeler gauges to check alignment.

Drum Sanders: Brian struggled with inconsistent sanding until he used a dial indicator to align the drum to the bed. Greg upgraded to a Powermatic with automatic feed-rate adjustment, reducing burn marks and snipe.

Greg, with a metalworking background, emphasizes the importance of leveling milling machines and welding tables:

Milling Machines: Must be leveled to prevent twist in the frame, which accelerates wear and reduces accuracy.

Welding Tables: A flat reference surface (like a cast iron table or granite slab) ensures precise fabrication.

Brian adds that his Langmuir Systems welding table transformed his metalwork by providing a reliable reference surface.

Not every tool needs millwright-level precision:

Mobile Tools: Bandsaws and drill presses on wheeled bases don’t require perfect leveling since they’re constantly moved.

Workbenches: While flatness matters, minor deviations (like Brian’s 1/16″ over 8 feet) are often negligible in woodworking.

Both hosts agree that taking the time to properly set up tools—whether it’s a table saw, jointer, or milling machine—saves frustration later.

Dial Indicators & Feeler Gauges: Inexpensive tools that make a big difference.

Revisiting Adjustments: Tools drift over time; periodic checks ensure ongoing accuracy.

Know Your Tolerances: Wood moves, so ultra-fine precision isn’t always necessary—but machinery setup should be as accurate as possible.

While most home workshops don’t need factory-level precision, applying millwright techniques to key tools can drastically improve accuracy and repeatability. Whether you’re dialing in a table saw or wrestling with a bandsaw, a little extra setup time pays off in the long run.