I started my first build of a Primo, however I’m stuck at squaring the base feet. My side measurements are very close, but the diagonal measurements are different by 1/4".
Would it be okay to continue with the next steps? I’ve tried repeatedly to get it closer with little success. Any tips or advice to fix it or can this compensated for later and not a big deal overall?
You CAN keep going, but I wouldn’t suggest it. The more square you can get it at this stage the easier it is to get square in the end. Ryan really stresses that in the Docs and for good reason.
I am sure someone will come along with a neat trick to help get them square. I unfortunately just keep trying until I get it right.
Starting with a really square top helps a lot
Keep at it.
As stated, the better it is NOW the better it will ultimately be. Your future self thanks you.
You can draw it up in CAD. if you specify the lengths as measured, all sides and the diagonals, CAD will snap it to its real-world shape. From there you can measure how far to move one corner in order to make it square. (Delete the diagonal measures to be able to move the corner, then measure again.
When I do this, I often start with an assumption that one rail is aligned to the X or Y axis, and that I will make both X and Y rails parallel (same length.)
The same trick works to figure out your offsets when squaring the end stops, though that is hopefully tiny if the machine base is square.
Thanks, I kept at it for the past hour and was able to get it just under a 1/8" difference. Will this variance be surmountable with the endstops?
Yes, that should be reasonably good.
Assuming you’re using a framing (or some other type) of square to lay things out, you may want to check that the tool you’re using is accurate enough for the task. Small angular differences get magnified the longer the lines get extended.
I’d use a 3-4-5 triangle method and a tape measure to draw out the right angles for the locations of the feet, then mark screw locations and measure diagonals before drilling any holes. It is a lot easier to relocate a drawn dot than to have to redrill holes so close to one another.
I’ve been using a yardstick, two rulers, and a tape measure as squaring guides. The variance diagonally is now around 1.5mm and I’m not sure I can get it much closer. Unfortunately, I learned the hard way about drilling a few holes too close together.
As for the z height leveling, the measurements vary a millimeter or less, will this be an issue or does the precision in the height of the legs need to be to the decimal?
Have you lined them up next to each other and made sure they’re consistent? I’ve seen some scary variance in lengths on measuring tools from different manufacturers.
Nah, you are going to plane the spoilboard anyway. 
Just a note for anyone that ends up in this circumstance… Usually if you are dealing with this, you can drill out your mispositioned hole to receive a wooden dowel that you glue in and cut flush, then you can mark/drill a new screw hole.
I seem to be particularly good at measuring twice and still messing it up, so I’ve had to use this trick a fair number of times.
One way to get this all straight.
What I did was cut 2 strips, about 3" wide and the length of the Y run on my table. I clamped 2 together and marked out the foot holes, and then used a drill press for where to put the feet. This let me have the 2 feet in the exact same relative position for both sides of the Y axis. (Thereby guaranteeing that the X axis rails will be parallel.)
I then set up a guide on the table to make sure that the strips would be kept the same distance apart as I slid them back and forth, guaranteeing that the Y rails would be parallel.
I screwed down one strip to the table and slid the other back and forth until the diagonals were equal. Once that happened I clamped the second strip in place, re-measured to be sure it hadn’t moved, and was still parallel to the first, then screwed it down.
Squaring the machine via end stops was simply using a piece of scrap to make sure the stops were the same distance from the corners, and checking.
Get a drywall square.
You’re welcome.
Your correct about checking and comparing tapes. I have found way to many tapes with differences in measurement. Also found out recently check the scales on your squares. 1/4 inch off the long side.
Looking close you could see the scale print was offset . Still good as a 90 degree measurement. Worthless as a measurement device.
Personal experience on this. I carefully shared my table out. Marked out the position of each foot and the screw holes. Everything dead to rights.
Mounted the feet mounts added the uprights and the side rails. Recheck the diagonal. Almost a 1/4 inch off.###*$. I couldn’t get it to square. Walked away for a day . Tube lengths were correct. After a lot of review I realized that 2 of the feet were not flat and not at a 90 degree angle. When I tighten down the feet angled in on one side and another side angle A slight angle Making a parallelogram. my printed parts were the cause. Reprinted taking more care and it all worked