Make your own simple, inexpensive tee slot bolts for table saw and router jigs.
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Step 1: Tools and Materials
bench grinder (optional)
fine emery paper
6mm x 50mm coach bolts
6mm x 25mm washers
Step 2: Square Holes in Washers
Using mini files square off holes in washers until they fit over the square shoulder on the head of the coach bolt. Chamfer one side of the square hole, so that it fits absolutely flush to the head of the bolt.
Step 3: Fit Washers to Tee Track
File or grind two opposite sides of the washers flat, until they slide snugly into the tee track.
Step 4: Flatten Dome of Coach Bolts
File or grind off the dome of the coach bolts until about 1mm thick. There is a slight flat on the sides of the heads that are a good reference.
Step 5: Test Fitting
Fit washers onto coach bolts and test fit in tee track. It may be necessary to file a few thou more from the coach bolt heads. Aim for a snug but smooth fit.
Step 6: Assemble Tee Bolts
Super glue washers to coach bolts, taking care to keep the chamfer the right way round. Polish all edges with fine emery paper until they glide in the tee track.