Instead of tilting blade for angles, why not leave blade at 90, and BUILD a couple of angled sleds to hold work pieces. Once your friends find out that you built a flag case, you will be asked to do more, which will be easy as you already have jigs to make cuts.
I have fixed the problem today. This afternoon I “re-tuned” the saw again with nothing more than a combi square and a lucky tooth on the blade. I was very meticulous and got it just right. Not much work needed to be done from where it was. Next I carefully aligned the fence to the miter slot. Before trying this cut again with the jig I left the saw at 45 and made some cuts with the miter gauge and the piece flat on the table and the cuts were perfect, so I knew the setup was right on. Then I set up to make the 67.5 cut. The only thing different I did was to clamp the piece to the jig with two clamps as Steve suggested. I clamped rather tight as I thought this really could be the problem. The cut was right on.
So the good news is that I fixed the problem, the bad news is that I’m not sure exactly what the problem was. Could have been a combination of a few things. So thanks everyone for your suggestions! Hopefully this can help others in the future that are having the same problem.
Hi Brian,
Please post some pictures of your finished flag case. I would love to see it!
Thanks,
David