I dabble in a lot of things - wood, plastic, metal, stone, leather etc. Years ago, my spouse bought me a Skil X Shop (long since discontinued, but still going strong). It has gone through fits and starts of activity, and makes an amazing amount of sawdust. >cough< >cough<
The one thing I struggled with was the miter slots. Skil chose not create this wee beastie of a saw with what is the more common 3/4" miter slots. Nope. let’s have 5/8th T-slots. I attempted to try and make some using high density plastics using the router table portion. Those did not work and I lost the investment in the plastic. I even tried to find metal to fit my needs, but wasn’t as versed in all things shop and the internet hadn’t really figured out how to be an e-commerce engine as yet.
A few weeks ago, I was looking for something entirely different, and my brain, which clearly never gave up, audibly clicked, and with 5 min. of vernier caliper work, and about 45 min. of FreeCad work, I had a prototype STL saved, pulled into Prusa Slicer, and sent off to the printer.
The first draft was printed at 5% density, so too weak for use, but just to test the fit. It was dang near perfect. So, two runs later, at 50% density, these were printed, not only did they not curl like the prototype, they feel as they will be very durable.
Improvements to come - create dovetail parts to allow printing any number of differing lengths to create miter gauge locked jigs of different sizes, create threads in the holes, and/or create hex shaped pockets so that’ll give better clamping force.
I’m actually not sure what I enjoyed more - drafting this in FreeCad (does that say something about my mind? ), and making it or finally solving an irritating design choice by a manufacturer.
I’ll probably put the resulting STL’s up on Printables or Thingiverse - to be determined.