Quote Originally Posted by Snapper View Post
You're using a drill vice, you're never going to get repeatability out of it, 0.1-0.3 isn't bad considering. They don't close evenly, the jaws don't shut parallel, they push the work up when they close and as you've mentioned because your part is thin it's susceptible to bending.

As I mentioned before, a jig plate would be a far more suitable fixture for the 2nd setup. Once made it would be much quicker to set up and a lot more accurate and repeatable.
No idea where to start creating a jig plate for these cases.