A 1:72 hangar for a model collection. 214 parts across 4mm and 2mm ply, roughly 3800 cut lines.
The real lesson: accumulated kerf
Individually every part was within 0.1mm. Assembled across twenty bays, the roof truss line was 2mm short of the wall. Kerf error accumulates and it does not care how good each part is.
Fix: I stopped compensating per-part and compensated per-assembly — measured the finished stack of twenty trusses, divided the shortfall by twenty, and added that back to each truss's spacing dimension. Second run assembled square.
Settings
4mm structural: 100% power, 8mm/s, 1 pass, air assist high. 2mm detail: 90% power, 14mm/s, 1 pass.
Engraved panel-line detail at 20% power, 200mm/s before cutting — always engrave before you cut, or your parts move.
Time
Cutting: eleven hours across four sessions. Assembly: still going, three weeks in, and enjoying every minute.
