I'm sorry for your difficulties.

If you have a zero clearance throat plate, it will not work when
you lean the saw over on a 45°. You need a plate with a wider
throat.

Your alignment tool sound plenty accurate enough. You should mark
some one tooth on the blade (felt tip) and check the same place on
the blade. Your blade would be really warped for this to make a
difference.

I have known saws that needed to have the hole(s) in the trunnion
enlarged to allow adjustment. I assume you have loosened the
trunnion bolt to the point of coming out to make sure the front is
loose, though it should only need to be loosened so a heavy blow
will move the end.

There is a set of alignment clips called PALS that make your task
easier: http://www.in-lineindustries.com/saw_pals.html

Here is one the best descriptions of what you are trying to do:
http://www.in-lineindustries.com/alineit-test3.html

--
______________________________
Keep the whole world singing . . . .
DanG (remove the sevens)




"VeryLargeCorp" wrote in message
oups.com...
I noticed the problem when I re-adjusted the blad to make a 45
degree
cut. I couldn't turn the blade to full 45 without it hitting
the
throat plate. That alone made me think something was off.

I have been measuring to a marked point on the blade using a
stick
with a screw in the end clamped to the miter bar. Not the height
of
accuracy I know, but accurate enough for the distance I'm
seeing,
close enough?

DS