When I said "I have access", that means I don't own the Delta 540 planer. I'd like to get a planer of my own that can do the job with a lot less hassle. The problem is that the boards are uneven thickness along the length. They were cut on a bandsaw type sawmill which combined with a few large knots in some of the wood makes me have to run at least 2 passes through the planer to get a smooth surface. This planer binds the wood if the board thickness varies by more than 1/16 of an inch along the length so it may cut great on one end and then bind before the other end gets through. So there are two problems, underpowered at 2 hp and the design binds on thickness variations.
I am better equipped than most to sharpen things. Please presume that I was able to sharpen the blades to sharpness that would shave without burning the steel or removing the temper. I used a diamond stone to set the edge and get the sharpness I wanted. I also made a custom jig from wood that allowed me to set the proper angle. It took 20 minutes per blade to remove enough metal to get rid of the gaps and produce a nice clean flat sharp edge. I already have a trip planned tomorrow during which I will pick up new blades. I have to travel a minimum of 60 miles to get to a store that sells them. If I have to go that route, I will run the wood first pass with the old blades and then put the new blades on for the final smooth cut.
Re setting the blades to ensure thickness across the board is consistent, I used a fine file to make a tool out of soft stainless steel to adjust height. It is simple to put the blade in and tighten the screws just enough to hold it in place, then use the tool to press the blade down into the slot to the proper depth. Tighten the screws evenly across the roller and the blade will be even enough to satisfy the most demanding furniture maker.
I stood by the sawmill as the trees were cut and I loaded the wood in the truck unstacking it from the rail cart. Very little sand or dirt will be on this wood. That does not mean it is totally clean. It is a lot cleaner than most rough cut lumber. I paid 80 cents a board foot which is "dirt cheap" for good quality cypress. As for why I want a 12.5 inch minimum width planer, it is because I am building Dadant hive bodies that are 11 5/8 inches deep. I have to purchase lumber 12.5 inches wide to allow for shrinkage while drying. Even though most of it shrinks below 12 inches, there are a few boards that are a bit wider. I prefer to get a planer that can handle the extra width without having to run the lumber through a saw first to get it down to 12 inches wide.
I dried this lumber in my greenhouse. Summer temperatures get up above 120 degrees if I close the door and open only a small vent. I've had it in the greenhouse four months now. This wood is under 8% moisture.
If you want to read a bit, google "best thickness planer under $1000"