I came home and finally remembered to measure the parts of my saw system. 
My saw has a 2 3/8 maximum depth of cut.  The plastic shoe holds the saw 
off the guide 3/8 of an inch.  The guide itself is 1/2 inches thick.  So, 
if everything were dead on, I should be just barely able to cut through 1 
1/2 inches.  However, if the lumber is a 32nd thicker, or the max depth of 
cut is a 32nd less than 2 3/8, or the thickness of the shoe or track is 
more than what I measured by a 32nd, any combination of those could easily 
add up to a 16th short on my cut.  Which is what is happening.

I am certain that my saw is sitting in the plastic shoe properly as it is 
just a flat piece of plastic on the top side.

I often do just use the edge of the guide as a straight edge and calculate 
the offset, but my saw also happens to have a weird offset measurement, 
and I have messed up that calculation a few times, which is why I got the 
saw guide in the first place.

Anyway, there are ways around all of this, I was just wondering if other 
folks had the same saw guide system and were running into the same issue.

I can also just find a 7.25 saw that has a 2.5 inch max cut.

Thanks for all the comments.

-- 
Blue skies.
Dan Rossi
Carnegie Mellon University.
E-Mail: [email protected]
Tel:    (412) 268-9081

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