Bosch GTS 10 XC sliding sled T-nuts replacement

The Bosch GTS 10 XC table saw is a good job site saw but if one wants to use it for fine furniture making, the preciseness has to be hardly achieved by finetuning almost every single aspect of the saw.

The sliding sled, which the saw originally comes with, is one of those. The T-nuts mounted from underneath have a decent play running in the rails, which can cause a huge angle deviation the longer the board (or piece) is.

There is a bunch of commercial products available in Germany, but I didn't want to pay 30+ Eur for a 3D printed product, especially if I also have a 3D printer at home, knowing I could buy 1kg PLA spool for less than that.

I measured the original T-nuts (the sled comes with 4 in total, two for each rail) and used the free 3D modelling tool - Onshape. The whole process took just 3 tries and less than an hour:

1. I tried with a width of 24mm, however the printed product only had 23.58mm and was even smaller than the original piece.
2. I tried with 25mm, thinking the printer simply prints parts a little smaller, however this time it was exactly 25mm wide and already over 0.5mm wider than necessary. I could have ended here and simply sand or scrape away material to get to the proper dimensions, however I also wanted to give this back to the community, as I hate those losers asking a lot of money for simple things that only take less than an hour to develop (3D-designing and whole testing included).
3. The final attempt was setting a width of 24.5mm, which printed, again, a tad smaller (at ~24.38mm) but wide enough to be still stiff in the rail.

The model comes with a small test piece that prints in ~10 minutes (using 6mm nozzle and standard speeds). Print this first and test the fit. Depending on your printer, material and settings it may require a tiny up- or downscaling (or hopefully no changes other than post-production).

In my case, I only needed to shave two-three thin shavings along both sides to get it past the beginning of the rails (no idea why they are stiffer at the beginning and end in my case) and then it slides in smoothly, without any play at all! Win!

Final hint - do not overtighten the screws when mounting the new plastic T-nuts, as they will cut their own thread. Otherwise the thread may break and the screws won't hold properly anymore.