OK .. I understand the mechanics of making a DUPLICATE of an existing insert. In my case the top of the saw is not flat from corner to corner and the miter slots are sharp causing binding for anything moving in the slot. See the attached image.
so I will take a piece of birch plywood and put three pieces of birch plywood on top separated by "perfect" aluminum miter slots. The center of the three will need an insert cutout. See image with no orange. A template with a hole for my pattern would work to make the place for the insert. Similar to inlay process, I was thinking that if I use a bushing with OD of 3/8" for the saw top and switch to a bushing with an OD of 7/16" but same template and bit, when I cut the insert it SHOULD make an insert that is 1/32" smaller all around (if I understand the process correctly). See image with orange insert. Once I have an insert that fits proper, I can make that insert into template and all others made from it will be exactly the same.
I haven't started building yet, so if you all have any other suggestions of a better/easier way, please let me hear it.
I don't understand inserting images. why can't I put it in middle of what I am explaining??
Last edited by dmac257; 02-26-2018 at 04:15 PM.
Reason: images not in order.