I've had square blocks clamped to the job and the alignment still ends up askew.
It sounds like you've tried harder than I have! It's reassuring (for me) to believe there isn't an easy solution and my badly aligned lettering is just how things are.
I think that's about the size of it.... there's probably a career in getting letters to align....
@MrE started
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I've had square blocks clamped to the job and the alignment still ends up askew.