![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_125606-01-1140x855.jpeg)
Mitre bar replacement
It looks like only Bosch, Skil and Ryobi make 16 mm slots (5/8″). You can’t buy a high-quality mitre gauge replacement, you have to make it yourself. So I bought a 16 mm mild steel flat bar and made a mitre bar that has no play. The idea was simple – resize the bar from 16.0 mm to 16.3 mm (5/8″ to 41/64″ which is an extra 1/64″) by hammering. The method is not very sophisticated but it worked just fine. I don’t have an anvil so I used a sledgehammer instead.
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_131051_HDR-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_134123-01-1140x855.jpeg)
It’s not easy to show the progress in pictures, but I flattened the bar in 4 places on each side, which is 8 places in total. I got a width of 16.3 mm which filled the slot nicely, without any play. If I went too crazy with hammering I used a file to go back to the desired width and to keep all 4 spots in line.
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_142558-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_151142_HDR-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_141218-01-1140x1520.jpeg)
Drilling and cutting threads was the next step. I just duplicated the original piece. The pitch in threads was different so I couldn’t use the original knobs and bolts.
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_165319-01-1140x854.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_171108-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200229_174201-01-1140x855.jpeg)
One more thing had to be done to prevent my new bar from falling into the slot. I drilled a hole at the end of the bar, cut the thread and installed a little screw, a washer and a spring washer.
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_120028_HDR-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_120301-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_123024_HDR-01-1140x855.jpeg)
Excess material had to be filed down from the other side. Once that was done I applied some 3-in-1 oil to protect my new bar from rusting.
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_125619-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_125518-01-1140x855.jpeg)
The bar seems to be working OK and it wasn’t expensive to make. It has no play and that makes me super happy!
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_125636-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_125606-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_125543-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200301_125455-01-1140x855.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/03/20200328_121722_HDR-01-75x75.jpeg)
![](https://rolandrolson.eu/wp-content/uploads/2020/02/20200215_114033-01-75x75.jpeg)
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