Modifying an Incra Miter Gauge to Fit an Oversized Miter Slot - Router Forums
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post #1 of 7 (permalink) Old 02-04-2019, 12:39 AM Thread Starter
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Default Modifying an Incra Miter Gauge to Fit an Oversized Miter Slot

I have a Bosch router table with a 12mm, but the slot width actually measures 0.786". I bought an Incra 1000SE Miter Gauge a couple months ago and have been foiled at using it because of the oversized slot in my table. The Incra miter bar has expansion discs to adjust to fit variations in the standard 3/4" wide miter slot, but the extent of expansion was to just 0.760". I didn't like the slop of the miter bar and felt the accuracy of the 1000SE would be compromised.

It took me a while to settle on "how" to compensate for the over wide slot. At first, I thought of making larger expansion discs and milling out the pockets to accommodate them. Too much work and I couldn't be sure it would be enough. Then I thought of adding a shim to the slot to narrow it so the stock Incra bar/discs could be used. I wasn't sure just how to add such a thin shim, too thin to screw down and I didn't like the idea of using adhesives.

I settled on drilling and tapping horizontal 1/4-20 holes along the bar and inserting nylon 1/4-20 socket head set screws on both sides. With a hex key, it is easy to adjust the set screws for the additional width that was needed and being nylon, provide some easy sliding. I crimped the threads a bit to make them a bit snug so they wouldn't loose position as easily.


It took some fiddling to figure out the easiest and fasted way to adjust the set screw heights, as I wanted them to be the same all along each side, there are six on each side. Once it was adjusted, there was no perceptible sideways movement but it slide along the slot very easily. Part of my design criteria was that it should be easy to adjust and change because I may want to use it on my bandsaw and disk sander and they have more standard 3/4" slots. I haven't tried switching it yet, but set screws on both sides of the bar, I am hoping one side can be set to work at the 3/4" width (with the other side fully recessed) and to other side for the Bosch table with the wider slot. I could not figure out how to do that with larger expansion discs.


I used the Incra 1000SE Miter Gauge for cleaning up slots in brackets for my daughter's rug loom. It worked beautifully.

Rick
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post #2 of 7 (permalink) Old 02-04-2019, 01:05 AM
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layered UHMW tape to the side of the miter rail...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

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post #3 of 7 (permalink) Old 02-04-2019, 08:51 AM
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Nice; I have the same, but reversed problem; bought an Incra V27 miter gage and it won't fit into my ancient Craftsman 10" contractor table saw, cause the slots are too narrow and I never thought to measure this first, duh!!

Since the saw is packed away in the basement, I have some time to think about how to fix it.

1) Buy a real saw, to go with my new to me Excalibur high end fence
2) Mill out the table slots, leaving the side closest to the saw true and original
3) Make a new mitre slide by cutting down a standard one - already bought one so that may be the best option.

Thoughts from the experts?

Thx

Paul
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post #4 of 7 (permalink) Old 02-04-2019, 09:09 AM
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new fitted rail...
Nickp likes this.

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

Stick....
Forget the primal scream, just ROAR!!!
"SNORK Mountain Congressional Library and Taxidermy”
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post #5 of 7 (permalink) Old 02-04-2019, 09:15 AM
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Quote:
Originally Posted by stick486 View Post
new fitted rail...
+1...
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post #6 of 7 (permalink) Old 02-04-2019, 10:37 AM Thread Starter
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Quote:
Originally Posted by Stick486 View Post
layered UHMW tape to the side of the miter rail...
Thanks. I did not know about this material. Mods to this one are done and I like that it is transportable between machines with the set screws. If I put that on the bar, the miter gauge would only be usable on the router table. I'd be more inclined to put it on one or both sides of the miter slot on the router table so the miter gauge could be used on all three machines.

But, I have ordered a roll of it because it clearly will be a useful material.

Curious though, the nominal thickness listed is 1/32" but in the product item line, it is shown as 0.025" thick. That makes a difference. The thickness that needs to be made up in the case of my router table is 0.050". If the tape is 1/32", I could only get one layer on, which would still leave some slop. If it is 0.025", I might be able to get two layers (one on each side). If that were too tight, I would file out some clearance in the table slop. I think if might be easy to do that, as there is paint or powder coat covering both sides and the bottom.

Rick

"If you want nice, clean, fresh oats, you must pay a fair price. However, if you can be satisfied with oats that have already been through the horse, that comes a bit cheaper."
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post #7 of 7 (permalink) Old 02-04-2019, 10:48 AM Thread Starter
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Quote:
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...snip...
3) Make a new mitre slide by cutting down a standard one - already bought one so that may be the best option.

Thoughts from the experts?

Thx

Paul
New miter bar sized to fit the table slot. You could make it from any bit of bar stock that fits your table slot (or modified it to fit), as there are only four threaded holes that you'd need to put in if you didn't need their expansion discs, which hopefully, you wouldn't because you would size the bar to fit the slot.

Rick
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