Zero Play Guide Bars for table saw miter slot

The zero play guide bar system is a huge benefit for anyone making and using jigs in a climate where conventional wood guide bars will expand and contract. I will use this with my table saw miter slot but you may find it useful with your band saw or router table.

Microjig has devised a nice solution https://www.microjig.com/products/zeroplay
I relied upon the users manual to inform my design and hardware choices.
https://www.microjig.com/user-manuals#zeroplay see “ZEROPLAY User Manual”

This current model has adjustability to fit slots from 0.688-0.774in (17.5-19.7mm)
STL UNITS ARE IN INCHES

There are two configurations for this design. One uses heat-set inserts, one uses a little bit longer fasteners into low-profile hex nuts.

BOM
--- For Assembling the bars for heat-set insert configuration ---

2 - top_V2_in.stl prints

2 - base_in.stl print

12 - 8-32 thread size, 0.185" installed length heat-set inserts for plastics (mcmaster: https://www.mcmaster.com/#93365a140/=1c5hk4f)

6 - 8-32 thread 3/16" long button head hex drive screws (mcmaster https://www.mcmaster.com/#91306a264/=1c5hkqt)

--- For Assembling the bars for hex nut configuration ---
2 - top_V2_nuts_in.stl prints

2 - base_nuts_in.stl print

12 - 8-32 thread size Narrow Hex Nut
(https://www.mcmaster.com/#90760a009/=1ccrera)

6 - 8-32 thread 1/4" long button head hex drive screw
(https://www.mcmaster.com/#91255a190/=1ccrmoc)

--- For attaching the bars to your specific jig ---

6 - 8-32 thread 1/2" long* pan head screw (mcmaster https://www.mcmaster.com/#91735a194/=1c5hman)

6 - #10 flat washer (mcmaster https://www.mcmaster.com/#92141a011/=1c5hmtj)
To adjust, you will need a 3/32" allen wrench

Follow the user guide (linked above) for the setup/installation. I did NOT create a stop piece for setup, as you can easily use a clamp and scrap materials to the same effect.

After printed parts were removed from printer, I used some sandpaper to touch-up the long faces of my prints (there was a little deformation around the knit line). I also suggest that you flatten the bottom face after installing the inserts as material will swell around the holes on the underside.

*This length with change depending on how thick the base plate of your jig is or how deep you're counterboring into that material.