I spent a few hours today retrofitting my cross cut sled for the R4511. I built it originally to use with the TS2400. I removed the front fence (closer to me) and jointed two edges on the JP0610. The wooden runners received screws on their sides to minimize lateral play when slid into the miter tracks. They are secured to the sled with countersunk screws.

The final procedure is to square the front fence to the blade. I use my 12" combination square and only able to get the right side squared to the blade. The left side has a tiny gap that I illustrated in the drawing below. The gap is exaggerated to make a point.

This makes no sense to me. Either my combination square is not squared or the blade's thickness is not uniform. The fence is flat as it is jointed. I am certain I am not seeing something very obvious. But what?

To make matter worse, I used the sled to cut a square panel about 8" x 8". One edge is jointed first. The remaining edges are cut, referencing the previous edge. The first two corners are square. The third corner is off by a tiny, tiny bit. The fourth corner is off by a larger amount. So I concluded that my sled is not square.

I went back and check with my combination square. The picture below tells that story.

The final procedure is to square the front fence to the blade. I use my 12" combination square and only able to get the right side squared to the blade. The left side has a tiny gap that I illustrated in the drawing below. The gap is exaggerated to make a point.

This makes no sense to me. Either my combination square is not squared or the blade's thickness is not uniform. The fence is flat as it is jointed. I am certain I am not seeing something very obvious. But what?

To make matter worse, I used the sled to cut a square panel about 8" x 8". One edge is jointed first. The remaining edges are cut, referencing the previous edge. The first two corners are square. The third corner is off by a tiny, tiny bit. The fourth corner is off by a larger amount. So I concluded that my sled is not square.

I went back and check with my combination square. The picture below tells that story.

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