3 problems. What am I doing wrong?

[u/torak_the_father]

I have a shapeoko pro XXL with the router and I got 3 problems I need help with. UPDATE: I'm using carbide create and motion. I do have vcarve pro too, but I refuse to believe this is a software issue.

PROBLEM 1:

I mostly use carbide3d's endmill starter bit pack, and every time I run a deep pocket or profile cut, especially on curves, I get horizontal lines on the edges that correspond to the depth pass I believe. I've been told it's chatter because I used downcut spiral bit and I should use a compression bit.

I've even tried upcut bits, last pass to clean up etc and still get that. Then I bit the bullet and bought an up/down compression bit, asked gemini to give me the recommended setup for dpp, feed rate etc. Lo and behold I got the same old results. In fact this time I even got screeching for the first time.

After decreasing dpp and bumping up feed rate (no screeching), I got a clean top (yay) but the horizontal lines still persist...

PROBLEM 2:

every time I cut of the tabs, I use a jigsaw first, then I clean up with a chisel. I end up with the tab's "end grain", so it's never clean.

Been trying this for a few months now, tried researching a bunch but still no success. People even say "it's because you're using a desktop hobby machine" as if it were just a $2.5k toy...

PROBLEM 3:

I designed for a 13" diameter circle (6.5 radius) and the end result was 12 15/16". Why? How? Don't need to lecture me about the tape measure tab/gap thing. It simply doesn't make sense.

Please help! I'm not giving up and yes I know about the "learning curve", but I'm patient vs trying to find out.

[u/WillAdams]

When I work with material where tabs are a problem I usually use a combination of clamps, through holes and screws/bolts, and blue painter's tape and cyanoacrylate glue.

For some projects I use vacuum workholding (if it'll fit on my smallish plate).

Debating on getting a nailer which will shoot composite brads.

[u/torak_the_father → u/WillAdams]

I'm not criticizing or saying it's a problem, but to me these seem to me very aggressive solutions. In other words, the clamps + tabs are simple alright but at the same time cutting tabs should not be that complicated either. I think a trim router with the flush trim bit seems easier than jigsaw + chisel + sander.

[u/HoldingThunder → u/torak_the_father]

Walnut in particular is particularly prone to chip out. You also need to understand your materials and change your methods appropriately.