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Spent 14 hours chasing a 1/16 inch gap on a face frame, turned out to be my own shop light
Customer wanted a maple vanity with a perfect flush face frame, and I told her no problem, two days max. I glued up the frame on Tuesday, let it sit overnight, and Wednesday morning I checked it under my bench light and saw a gap along the center stile. I pulled the clamps back out, re-squared everything, and re-glued. Still there Thursday. I checked my table saw fence, my miter gauge, my planer knives, even ran a straight edge across my assembly table, and everything read dead flat. So I did what any stubborn guy does and re-cut the whole stile, thinking the wood had moved on me. Nope. Friday afternoon my wife walks in, flips on the overhead fluorescent because she couldn't see, and that gap vanished. The light from my bench lamp was throwing a shadow line that made the joint look open when it was tight the whole time. I kept standing in the same spot every morning, same bad angle. Has anyone else burned a whole workday on a shadow or a reflection instead of an actual problem?
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