Zero Play Guide Bars for table saw miter slot

thingiverse

The precision guide bar system is a game-changer for anyone working with jigs in environments where standard wood guide bars expand and contract. I plan to use this with my table saw miter slot, but it may also be useful with your band saw or router table. Microjig has developed a clever solution that can be found at https://www.microjig.com/products/zeroplay. I relied on the user manual to inform my design and hardware choices. The current model offers adjustability to fit slots from 0.688-0.774in (17.5-19.7mm), with each guide piece measuring 8.94" (227mm) in length. One guide set can fit diagonally on a 200mm x 200mm build plate. This design comes in two configurations: one uses heat-set inserts, while the other employs longer fasteners into low-profile hex nuts. Bill of Materials: --- For Assembling the Bars for Heat-Set Insert Configuration --- 2 - top_V2_in.stl prints 2 - base_in.stl print 12 - 8-32 thread size, 0.185" installed length heat-set inserts for plastics (available at McMaster: https://www.mcmaster.com/#93365a140/=1c5hk4f) 6 - 8-32 thread 3/16" long button head hex drive screws (available at McMaster: https://www.mcmaster.com/#91306a264/=1c5hkqt) --- For Assembling the Bars for Hex Nut Configuration --- 2 - top_V2_nuts_in.stl prints 2 - base_nuts_in.stl print 12 - 8-32 thread size Narrow Hex Nut (available at McMaster: https://www.mcmaster.com/#90760a009/=1ccrera) 6 - 8-32 thread 1/4" long button head hex drive screw (available at McMaster: https://www.mcmaster.com/#91255a190/=1ccrmoc) --- For Assembling the Metric Bars for Heat-Set Insert Configuration --- 12 - M4 heat set inserts (available at McMaster: https://www.mcmaster.com/#94180a351/=1cjbptu) 6 - M4 x 0.7mm thread - 5mm long button head hex drive screws (available at McMaster: https://www.mcmaster.com/#91239a136/=1cjbqk5) 2 - base_metric_mm.STL (STL units in millimeters) 2 - top_V2_metric_mm.STL (STL units in millimeters) --- For Attaching the Bars to Your Specific Jig --- 6 - 8-32 thread 1/2" long* pan head screw (available at McMaster: https://www.mcmaster.com/#91735a194/=1c5hman) 6 - #10 flat washer (available at McMaster: https://www.mcmaster.com/#92141a011/=1c5hmtj) To adjust, you will need a 3/32" allen wrench. Follow the user guide for setup/installation. I did not create a stop piece for setup, as you can easily use a clamp and scrap materials to achieve the same effect. After printing parts were removed from the printer, I used some sandpaper to touch-up the long faces of my prints (there was a little deformation around the knit line). I also suggest that you flatten the bottom face after installing the inserts as material will swell around the holes on the underside. *This length may change depending on how thick the base plate of your jig is or how deep you're counterboring into that material.