Adjustable Miter Bar for SKILSAW SPT99T-01

Create a fully parametric 3D CAD model of an adjustable miter bar for a SKILSAW SPT99T-01 table saw. PURPOSE: The part is a replacement/DIY version of the adjustable miter bars used in the SKILSAW SPT99T. It will be manufactured by FDM 3D printing in PLA. MAIN DIMENSIONS: - Overall length: 270 mm - Nominal width: 19.0 mm - Height: 9.2 mm - Designed for a nominal 3/4 inch miter slot - 7 mounting/adjustment positions distributed along the 270 mm length PARAMETRIC VARIABLES: - bar_length = 270 mm - bar_width = 19.0 mm - bar_height = 9.2 mm - screw_diameter = 4 mm - hole_diameter = 4.3 mm - number_of_holes = 7 - end_margin = 18 mm - expansion_clearance = 0.15 mm - nut_width and nut_height must be editable - screw_spacing must be editable DESIGN: Create a narrow main runner that fits inside the table saw miter slot. The runner must have an adjustable expansion mechanism similar to commercial adjustable miter bars: - The main body should have a longitudinal flexible/expandable section. - Adjustment screws should push an expansion section outward against one wall of the miter slot. - Include captured hexagonal nut pockets for the adjustment screws. - The adjustment screws must be accessible from the top of the bar. - Use 7 adjustment screw locations. - The adjustment mechanism must allow approximately 0.3–0.5 mm total width adjustment. - Do not make the expansion mechanism excessively thin; it must survive repeated adjustment in PLA. HOLES: Create 7 evenly distributed adjustment holes along the length. Use M4 screws. Provide hexagonal captured-nut pockets suitable for standard M4 hex nuts. Make all hole and nut dimensions parametric. PRINTING: Optimize the geometry for FDM printing in PLA. The bar should print flat on its largest face. No supports should be required. Avoid unsupported overhangs. Use rounded internal corners where possible to reduce stress concentration. IMPORTANT: The model must be a true parametric CAD model rather than a decorative mesh. All major dimensions must be editable parameters. The final model must be exportable as STL. Also provide STEP if supported. Include a dimensioned cross-section showing: - overall width - overall height - expansion section - screw position - captured nut - miter-slot contact surfaces.

Parameters

Every value above is a live dimension. Open a model like this in the editor and each one becomes a slider you can drag before exporting.