Stack and drill the holes to the exact size. Stack the first two then using the top one again, stack one or two more, drill, repeat. Anyway, that’s how I would do it.
I tell my students, First, pause to let the wood catch up to the blade. Back up just enough so the teeth are going to be in the proper position. Now lean on the side and go.
The hockey stick is caused when the set screw and the thumb screw don’t meet in the center of your blade clamp. Because it is the bottom clamp, I usually sit on the floor so I can see. Back out the thumb screw and see where the set screw is, then just adjusting until centered. The only hard part about this is getting back up off the floor.
Can’t help with the noise.
I have done it. I don’t clamp it. I get it wet, not soaked. Sometimes I will set it outside and let the NC heat and humidity work. I put something on it. I don’t want it to break, so nothing super heavy, just pressure.
I think that those that sell their work have a second saw in case the first one stops working. When I buy a better saw I sell my old one.
I started with a Craftsman then had a Dremel, next was the Dewalt and now the Excalibur. Only keep one. Always sold the old one.
I have the SawStop jobsite saw. I get quality cuts. It is not large and can be mobile. I also have 8 fingers and 2 thumbs. My contractor saw scared me. I would get kickback. Now I have better control because it is a bit smaller.
Do check YouTube. There is a large difference between a block plane and a bench plane. The sharper the better. And only reveal a very small portion of the blade (iron).
Cancel the card. Because you know of the problem, you contacted the card company, they might give you grief if you now try to correct a mysterious $15,000 problem.!
I once did a test, I was cutting a piece of cherry and it was smoking. Without removing the piece I just added a piece of packing tape to the top of the area I haven’t started to cut and continued on with my cut. Nothing else burned. To me that was proof enough.
I also always use the clamp for holding compound cuts.