hey tim...to start, that is a split nut set up I had in my "extra parts" drawer...as it turned out, it fit perfectly on my recently acquired 1500...but as fate would have it, the half of the nut that does have the threads, is a perfect match to my larger machine(1 1/4" wide)...your suggestion of widening the split is excellent, but I cannot do that since I encapsulated the split nut so it cannot "twist" out...perhaps a bit dangerous, as if the machine has a problem, the nut won't be the part that gives way and something else will break...living life in the fast lane!...LOL!...but on the flip side, I would not want the nut to loosen and ruin a work piece...pick your poison!...and as far as the wear patterns, as shown in the photo, they are not wearing deeper...they are wearing sideways only...sorry for the poor picture quality...so sanding the block will not help in this situation, on this particular block...but I don't know if any blocks do wear deeper, as I have a few that have all worn sideways(I save everything!...even useless, worn parts...LOL!)...I will be making new, split nuts so the 3-D printer thing sounds interesting, but I would have to see a part made to judge if the tolerances are acceptable...the casting idea seems doable, but I do a lot of casting and there can be shrinking issues so maybe the tolerances become too tight...so, like the saying goes, "you go home with the girl you brought to the dance!"...I will be tapping!... old school!...LOL
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