After setting up my miter saw. I needed a stop to do repeat cuts that would be accurate and last through years of use. 8020 makes a part that is used to connect their product in many configurations and angles. I found this to be perfect for a flip stop.
The stop needs to flip out of the way if needed to make cuts without having to remove or change the location. This presents a problem. How to have it move up and down without being loose and inaccurate.
This is the secrete to the flip stop. I used a bolt and a oillite bronze bearing. You need to find a 5/16" bolt with a length longer than 3/4" that has no threads. The bearing will fit tighter with less slop if it's operating on the non thread section of the bolt.
I had to cut the threads deeper on the smooth section until the bolt bottomed out tight to the stop slide but didn't tighten down on the bearing. Stopping the threads short will act as a shoulder and allow the bearing to move but not loosen the screw. I later picked up some shoulder bolts on EBay that I will make a second stop with. Just tighten the bolt until the bearing no longer has any side to side movement.
Here the bolt and bearing are screwed into the slide. The wide flat surface of the stop helps insure the flip stays square and aids in strength. Now all you have to do is make the flip stop fit snug when the bolt is tight. Drill it out to fit the bearing OD with a friction fit. Maybe a little glue. If it wears it's easily replaced for about $3.
Complete with the wood flip stop. The important factors that make this accurate and strong.
1) Base slide from 8020 less than $5. Wide surface to insure it's square.
2) Shoulder bolt with bearing. ID 5/16 OD 1/2 length is 3/4.
3) Slide rail from 8020 6' long. 1.5"X3". 8020 found on eBay for less than $45. These are very stiff and straight.
Al B Thayer
Friends don't let friends use stamped metal tools sold at clothing stores.