Ugggh.... I really feel for you. I had a Delta table saw that I periodically checked the alignment on. And, 1 day low and behold, the alignment and was way off, much like you described. I wrestled with that machine for over a solid month. Nothing worked, and I refused to re-drill, thinking that if something was truly bent it would just mask the real issue and create a bigger hazard. After all, a bad accident on the saw was what I was trying to prevent. In the end, the saw won and I gave it back to Delta for them to figure out for their own product research. The only thing I could figure is that on day something bound up a little bit, and in the process of cranking on the assembly, I bent something. My new saw was a Craftsman zipcode saw. I shunned them at first, but when I looked further I understood the benefits of cabinet mounted trunions. I have adjusted my saw once at setup....took literally 15 minutes and had a perfect .003 from front to back...it was heaven. Sorry for your misery....truly I understand.