Mark2's comments are spot on, it takes very little fore and aft movement at the slip joint to move the head of the sawframe sideways quite a bit.
Can you give some measurements:
- How much does the sawframe have to move sideways to clear the base at the switch?
- Is the run of the blade between the guides parallel to the slot in the base casting?
- Is the blade central in the slot, if not by how much and which way?
It's worrying not to know why the change occurred, but if after due consideration you can't find the reason, I'd just increase the length of the spacer and have done with it.? These no down side to this and its reversible when you do finally find out why - jv
John Vreede