Here are the pictures I promised. They key things are:
1. The paper instructions which come with the Align Power feed are awful. Go to Precision Matthews website and download the newer (and much better instructions). The paper instructions have you putting the gear on the handle-shaft backwards.
2. Getting the mounting plate LEVEL with the table is vital. Otherwise you will get tilted/pinching gear engagment.
3. Cut a narrow strip of paper to run through the gears to check engagement. It should perfectly fan-fold the paper, without tearing it, but it should leave a clear mark where the teeth squarely engaged with NO Taper. You should do this test with the X-Axis feed moving at a very slow rate. If it is pinching too hard, or tearing the paper, or slowing the motor, then you have the gears meshing TOO Tightly. Use the picture of my test paper as the "gold standard" for engagement. My gear engagement is much lighter then many I have heard, but is still very secure with no "slap/play".
4. I have provided a picture of the install of the limit switch. Do it like this, and all will be well. Just make sure to KNOW where your Stops need to be placed to avoid over-extending the table. This is especially true if you wish to protect your DRO scales.
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