Totally bewildered, I almost called it a day and left the workshop out of disgust. I went to reach for the lightswitch and a little voice in the back of my head whispered "Try a new drill bit!".
I turned around and reached into the toolbox for a new 5/32" bit. As I broke the plastic on the black and yellow packaging, I had my doubts. I had never seen a worn bit drill crooked, and the one I was using was still very sharp and didn't display signs of wear or dulling. But, I chucked up the new bit and drilled through half a dozen tenons of 1/4" delrin one right after another - with loosening the tailstock between each, and even swapping bits. All of them were perfectly straight, and I felt rather foolish.
Check the simple things first. I drill this into my engineer's heads every day. Check the easy stuff - the cable, the receptacle, the switches, move the cable to a new port, did the user sign on correctly, etc. You should have heard the cursing after I realized that I wasted almost two hours of time over a $2 drill bit.
