Inexpensive Snug Miter Bar
No wiggle in your jig(gle): I make a lot of jigs and fixtures that rely on a snug-fitting bar to ride in a miter slot. My inexpensive hardwood miter bars adjust for a perfect sliding fit.
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Start with 3/8"-thick maple strips ripped for a loose fit in the 3/4"-wide miter slot. Drill 3/16" holes to form the ends of expansion slots located 3/16" away from one edge—one centered and one on either end of the bar. Use an 1/8" straight router bit to complete the slots. Drill and tap for 10-24 threads in the side of the miter bar, centered on the length of the slots. Use 1/2"-long setscrews to adjust the fit in the miter slot.
