Mitre Slots with tapers

On 26 Jan 2005 07:12:40 -0800, "FriscoSoxFan" <[email protected]>
wrote:

>I have a DW744 benchtop saw. Before the flames begin, I am quite happy
>with it and don't have the footprint for a contractor's saw. That being
>said...
>
>The mitre slots on it seem to have tapers at the front and back that I
>can't seem to figure out. Crude ascii art:
>
>/ \
>| |
>| |
>| |
>\ /
>
>I cannot figure out any way for a mitre bar or runner to not have slop.
>If it fits in the front opening, as soon as it is past the opening
>there is slop. if it fits tightly in the center of the runner, it has
>too much resistance at the front or back opening.
>
>Am I missing something, or should I follow my impulse and break out a
>file and strighten those tapers out? If so, what is the best way to go
>about this to reduce the chance of over-correcting?
>
>Since this is a google groups posting, I'm sure I have been filtered
>out. If not, thanks in advance.
>
>Jay


the top is aluminum, no?

I think I'd make a strip of wood that fit tight in the slot, a little
shorter than the fullwidth section and a not quite 3/4" taller than
the depth. seat it in the slot.

take a couple of pieces of 3/4" ply with nice straight edges and clamp
them tight to the first piece.

use a router with a pattern trim bit to *carefully* straighten the
slots.