Join Date: Jul 2008
Location: Florida Panhandle
"After two hours of test cuts in MDF, the closest I've gotten is 0.002" too large, or 0.004" too narrow. The former doesn't fit, and the latter has a detectible wobble."
Either of those dimensions is perfectly acceptable. If it is the 0.002 to large then simply lightly sand. 0.004 is a fine fit.
When I made my sled runners I never measured either the miter slot nor the runner that I cut. I just cut the oak very slightly large and sanded then it fit.
This is woodworking, not machining the cam bearings for your Ferrari.