I have done this a few different ways now, but have never really been satisfied with the results. I started out cutting steps into aluminum jaws and we know they will not last too long without resurfacing and recutting.
Now all I use is mild steel jaws for steps and use aluminum ones only for profile jaws or jig plates.

Now on the Haas, I want to try it a different way then I have in the past. I will be cutting all 4 jaws in a 4" double vise. I think clamping 123 blocks into the jaws and then modeling this up may give me my best chance for accuracy.

In the past I have just kept installing all new jaws on the same face of the vise. Rinse and repeat just jogging an axis. That takes no consideration for variation across the vise or table, so could show in the parts too. Certainly not a very accurate solution.

Any thoughts, tips or tricks?