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Variation between knives? I try for less than .001" but am not always that successful. I set them now with a jig I bought that uses magnets to hold the knives while I tighten the set screws. Does your jointer have the set screws below the knives or springs?
I used to use a straight edge or a jointed board and set it by "feel".
Make sure to check that the tables are co-planer before final setting of the knives.
 
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