Miter bars for jigs and fixtures

[Dave Lehnert]

I just got the new issue of WOOD Magazine today in the mail. The front cover shows "5 Must have Jigs from Plywood". One project is a sled. Sure they will have tips to help you out if you are a subscriber.
I have not looked at that issue yet so can't say what info is in it.

[Brian Henderson]

It has been six plus years and my UHMW runners still fits the slot perfectly:

http://www.sawmillcreek.org/showthre...ghlight=RUNNER

That's what I typically use for mine, I ended up making some hardwood runners for a crosscut sled, it works fantastic in the summer but in the winter, the runners swell and won't fit into the miter slots. I need to go grab some more UHMW stock and replace them, what I have on hand isn't long enough.

[Lornie McCullough]

Another vote for cold rolled steel..... bought a 20 foot piece locally, and now I never hesitate to make a custom jig for whatever.

Lornie

[Lee Schierer]

If your miter bar is too loose you can center punch dimples on one side to make it bigger. Start with small dimples until it starts to fit snug through out the length. If it is too snug it might be a good time to meet a friendly machinist.

The dimple method works, but tends to wear quickly. I purchased some UHMW tape that is a few thousandths of an inch thick and I apply a layer of that to the side of my miter bar and get a perfect friction free fit with no side play. The advantage is the entire length of the miter gauge bar gets slightly thicker, not just random spots. It lasts for years and is easily replaced if damaged.

[Justin Ludwig]

I make mine out of plywood. I rip,plane, and drum sand them to a perfect fit, then wax the bajezus out of them. Then I wax them some more.

[Joe Vogler]

Thanks for the tip. For the benefit of anyone interested, that would be the March 2015 Issue, #231.