@bar I did not, but I did feel like some teeth were seeing some wear.
@jwolter I was talking about the gears inside the gearbox - if you scroll up I had attached a couple of photos. My chain - chain sprockets have been good other than a sticky pin in a chain recently that sometimes causes a issue here or there. Since we are on the subject I can give an update:
Since having issues I reviewed your really great work on the Chain Geometry spreadsheet. Sure enough with my heavy sled and 12’ beam I had created a very accurate and precise machine but one that was doomed to failure. It did give me a data point to better understand the possible chain tension needs in the corner though. With my previous setup I was seeing a MIN chain tension of 10.59 in very bottom of corner so if i was getting accurate cuts 3 or so inches from that than likely ~13 lbs chain tension or greater could be what I need to keep good, accurate cuts across the entire board. I then decided to move to a 14’ beam at 27 lbs sled. My Chain tension does go down to 12.4 MIN in the bottom corners but offsetting as much as I can I think i get close to my 13 lbs of tension. So far so good, probably cut 4-5 in corners with little issues. The only issues i’ve dealt with lately are sticky chain at sprocket or some weird angle cutting as sled is slightly easier to left in different scenarios than my previous heavier sled. This just leads to cuts that are at a slight angle/“draft” maybe 3 degrees or so.