Ryobi RTS30 Mitre Bar

I wanted to make a saw sled for my Ryobi RTS30. Since this is a contractor saw, it doesn't use a standard miter slot. I searched the webs and didn't find one for my saw. Using the original Miter Bar as a guide I made this.

The saw is full of imperfections, so I had to adjust the model, 8 times before I got a good fit.  Around try 6, I made an undersized piece to wrap in some 220grip sandpaper, and clean up some of the OEM burrs.  That file is also attached.

Finally, I got a good working model. I printed the first pair for a Box Joint jig. When that worked, I printed 4, for a full sled.

I printed in PLA, 4 walls, 4 top and bottom layers, and I've printed at 35% and 85% cubic infill. we'll see how they hold up. 35% should be plenty.

Installation:  Once printed, I inserted the rails into the T-slots. Squared up the fence at the distance I wanted the edge of my board. Applied double stick tape to the rail, then layed the board on the rails/tape. Press down firmly.  Slide the assembly out the back.  Pre-drilled the 4 corner screws. Since I used ¾ plywood for my base, I used #6 x ¾ flat head wood screws.  Test the runners. If they were still good, drill and screw the center screw. Test fit again. 3 screws per rail should be plenty, but there are 5 for extra support. Finally I waxed the bottom of the sleds to get a good slide.