While setting up my new saw I needed a sliding base for my magnetic dial indicator. $5.35 with tax plus a scrap of oak and a few bolts 8x32.
I purchased an aluminum bar 3/4 x 1/8 (I couldn't find 1/4") and a steel 'construction' angle bracket, 3" by 4".
I cut the angle bracket so that I had a flat piece of steel about 3" by < 4" and about 10" of aluminum. Attach the steel across the mid point of the aluminum bar with bolts, pop rivits, whatever. Be sure to leave enough room for the magnetic dial indicator on the steel plate. Attach the wood block to the aluminum bar as a handle.
The aluminum bar should fit into your miter slot and you'll be able to slide the magnetic dial indicator across the table top. The dial indicator will move parallel to the miter slot.
Here is the trick that you need to make this work. The fit in the miter slot needs to be an "interference" fit. i.e. The sliding base needs to rub on the sides of the miter slot. To make this interference fit put the 3/4 x 1/8 bar in a vice so that the vice grips the 1/8" edges of the bar. Leave an inch or two sticking out of the vice. Then take a adjustable wrench and clamp it on the 1/8" edges also. Use the wrench to put a slight bend in the aluminum bar. This is difficult, but the bend is what makes the interference fit. You'll probably need to do this on both ends of the aluminum bar. If you bend too much you can adjust it with a little file work.
The interference fit is the only part of this jig that needs to be precise. Everything else just needs to be solid.
A company near us produces molding of all shapes and sizes. They have perhaps four people looking over plans and doing takeoffs, then bidding the molding for the jobs. Given that, it may be useful to...
Many times equipment manufacutrers purchase and use standard production gears. Have a look for a power transmission retail outlet near you and see if your gear can be matched up with a standard from...