I exchanged emails with Barry earlier today. He said we are right on with the troubleshooting recommendations. He suggested one other thing to check- At the 6" setting, is the readout straddling a joint between two sections of sensor strip? If joint is too wide, every measurement beyond that joint (farther from the blade) will be out by the same amount.
Also, he said the following calibration technique which requires a digital caliper, overcomes blade and fence problems and is being used successfully by a number of people (quote):
I just went out to the shop and tried the method Barry mentioned. BINGO!! It seems my problem is solved. I am a bit hesitant to say that it is definitely solved until I have an opportunity to spend more time in the shop making a few more test cuts. My frustration level is not quite as high now. Thanks to Alan, David, Barry, and all the rest of you who made suggestions.
ccasion1