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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
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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