Have a gaffrig 1" spacer i tried to test fit yesterday. Seems the cutout of the hole for the vertical shaft will not fit around the flange of the upper. Seems to be off by a good amount, 1/8" maybe.

I see there are models for bravo and sportmaster, but I don't see how this would affect the fitment to the upper. It was purchased used on there but looks brand new.

Any ideas?

i have spormasters and am using the regular bravo spacers. They is no difference other than cosmetic between the 2. Maybe you have one for a older bravo drive or a TRS or something?

Could very well be. took some pics which i will post tomorrow. Spacer cutout for the vertical flange is 2" while the flange on the bottom of the upper is 2.5"!!!! Far worse than I first thought last night.

Does a machine works tower protude below the upper casing??? I am thinking that could be my problem, but then figure plenty of people have ran a spacer with tower.

You have to machine the spacer to fit the MMW tower. If I remember correctly, you cut just enough to clear the tower not cut the hole larger. I suggest you call MMW to confirm.

Excellent suggestion! MMW - wow what a great company. Talked me through exactly what was going on and with about an hour on the mill I will be rockin' and rollin'!