Thanks for that, how I wish everything was that smooth on my mill!

It was nice to know that the "proper" way involves whacking things with a mallet. I forgot to add that I also use a DTI to check things, but instead of sticking it in a chuck/collet, I simply plonk the magnetic base on the side of the head. My vice doesn't rotate around a centre bearing, so I end up swinging it around one of the mounting bolts, which tends to make it a bit more fiddly to get right.

I will try that head-straightening techinique next time I feel mad enough to change it from it's present setting. Although I'm sure having the ability to rotate the head around can be useful, it does tend to make for one more thing to go out of true when you least expect it.

Sorry I can't help with your problem, my guess is similar to yours, in that you probably need to shim things to square them up.

Good luck!

Jeremy