Milling a table saw miter slot.

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Forum topic by Robert posted 04-26-2018 03:15 PM 976 views 0 times favorited 8 replies Add to Favorites Watch
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3482 posts in 1934 days

04-26-2018 03:15 PM

Hey guys.

I have added the table saw on the right to my shop. Quite disappointed to find 1) the miter slot is every so slightly narrower 2) quite a bit wider apart, rendering both my Jessem miter gauge & xcut sled unusable on it.

Came across on YouTube and was thinking about trying it.

At least I would be able to use the miter gauge and my single runner jigs.

What do you guys think?

Or is there another way to do it? The slot is about .010” narrower.

-- Everything is a prototype thats why its one of a kind!!

8 replies so far

View RobHannon's profile


301 posts in 984 days

#1 posted 04-26-2018 03:23 PM

How upset will you be if you mess up the miter slot?

I personally would try it but thats me. Cast drills and taps pretty easily, so in theory it should go fine with some prep and patience. Cutting cast will generate heat pretty fast, so id take lots of breaks and get a couple extra bits if you do commit to trying it.

View GR8HUNTER's profile


6348 posts in 1166 days

#2 posted 04-26-2018 03:47 PM

UUUMMMMMM i will be watching this as i hate my hole


-- Tony---- Reinholds,Pa.------ REMEMBER TO ALWAYS HAVE FUN

View Loren's profile


10477 posts in 4102 days

#3 posted 04-26-2018 04:19 PM

You can try filing first to see what that’s like.
I wouldn’t be afraid to use the router
personally but of course you have to get
it right.

View HokieKen's profile


10415 posts in 1592 days

#4 posted 04-26-2018 07:54 PM

Problem with a router on metal is speed. Cast iron is pretty friendly but you’re continuously putting carbide into an interrupted cut at speeds much higher than appropriate. But, it’s only .010 so it’s probably not a real safety issue and may work just fine. I’d use a bit smaller than the slot though to avoid it getting hung on both sides and getting 2 rough edges.

Honestly if were me, I’d go with file and a carbide scraper. It’ll probably be faster when you factor in setup time and definitely less nerve-racking…

-- Kenny, SW VA, Go Hokies!!!

View GrantA's profile


1704 posts in 1861 days

#5 posted 04-26-2018 08:29 PM

File with a safe edge should take off.010 without too much grief.

View RobS888's profile


2606 posts in 2299 days

#6 posted 04-26-2018 09:31 PM

Are the trunions table mounted? I’m asking because it looks like the gaps are reversed, sort of like the center table portion is reversed on the saw on the right.

-- I always knew gun nuts where afraid of something, just never thought popcorn was on the list.

View TheFridge's profile


10859 posts in 1940 days

#7 posted 04-26-2018 09:39 PM

Get a router speed control and go slow. I used a router sled to fix my potato chipped uni top and deepen the miter slots. Think I have a blog on it but it’s been awhile.

-- Shooting down the walls of heartache. Bang bang. I am. The warrior.

View John Smith's profile

John Smith

1924 posts in 616 days

#8 posted 04-26-2018 10:12 PM

I have accidently cut into a cast iron table saw top with my 2hp hand held router
with a 3/4” carbide tipped dado bit. it was about a 1/16” deep by 6” cut.
so I know that it can be done. if you use a router, you may have to
sacrifice the bit to get it done (on purpose).
I used Bondo Steel Epoxy to fill the gouge which worked quite well.


-- I am a painter. That's what I do. I paint things --

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