Required parts:

• 4'x4' 3/4" thick MDF
• 48" Universal double cut profile T-track, 3/4" wide, qty 8
• E-Z Look Threaded Insert, Hex-Flush, M6-1.0, 13mm length, qty 75
• Button Head Hex Drive Screw, M6-1.0 20mm long, qty 75

• 6 x 5/8 Wood Screws, qty 100

The stock spoil board is intended to be machined in place. With it mounted to the metal frame you can run the threaded insert portion of the base c2d file with a 1/4" mill. Optionally run the drilling pattern for the T-track mounting holes with a 1/8" bit. The origin for both operations is machine center, use the jog menu in Carbide Motion to move there. Make sure that this location on your machine is exactly in the center of your stock spoil board!

Once you run the operation, disassemble the washboard, install the threaded inserts, and swap the front and back spoil board pieces. Once everything is fastened in place run the same programs again, keeping the same origin that was set up in the first operation. If you centered the origin correctly you should have 4 rows and 9 columns of 9mm holes perfectly aligned. If you ran the T-track mounting holes they should line up exactly front to back as well. You'll have to remove the front spoil board to install all the threaded inserts.

If you've drilled the T-track holes, line up the holes in the T-track with the mounting holes in the spoil board, mark, and cut the ends of the T-track to fit. You'll want to cut the track approximately 3/4" (20mm) short er than the MDF in front and back so you can insert your bolts into the track.

With the track installed, measure the distance between 2 slats and rip 9 pieces of MDF that width.Depending on the tolerances of the track, this should be just under 3.25" wide. Cut these slats so they are the depth of your stock spoil board, which should be 39.5". It may be good to rip a few extra to practice the next machining operation on, as well as to create a few spares now when the current ones get chewed up. Create a fixture that will allow you to load one slat into the same position every time. In order to drill all the holes in each slat, each piece will need to be machined twice, once for each side. I used a simple "L" block to make this repeatable. The origin for this operation is the exact center of the board.

Machine both ends of each slat making sure to keep the topside up when rotating the board so the bolt pockets are on the same side. Once each slat is finished, install the threaded inserts and mount to the factory spoil board with 4 M6 bolts.