Well, I haven't yet completely solved my table saw cutting problem but I decided to move forward and complete the sled.
I stole a bunch of ideas from you guys, so thanks for that . Glen Butler's micro-adjuster construction and procedure really made aligning the fence a snap. I got it to 0.00025" over 18" by following these steps.
Mine is basically a copy of this sled. 30" x 24", 3/4" BB ply for the base and ash for the rest. All the hardware is from Rockler except for Incra miter sliders on the bottom. I bought a bunch of Incra T-track for the top originally, but then I discovered it requires a 1/2" deep channel and I thought it wouldn't leave enough material underneath for the screws. The Rockler T-track is only 3/8" deep, leaving 3/8" below for the screws.
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The biggest issue is that the miter slots in my table saw are not exactly parallel. There is no slop side-to-side, but they are off by just enough so that towards the end of the cut there is more resistance as the sliders bind up in the tracks. I don't think it will affect the performance though.
Thanks for looking,
Mike