If you are looking to get a more permanent solution to get the play out of Dewalt Router guide and the Festool track, this was my solution. A little work, but if you are decent with a dremel tool then you can have this done in 20 minutes or less. I guess you could also use a hand file but would be a very tedious task considering you have to preserve the bottom and side edge of the Cam and also you need a pretty consistent line all the way around. I suggest borrowing a dremel with a 561 MultiPurpose Cutting Bit, and a pair of channel locks.
This is the dewalt plunge router with the attachment ($45-50) with Festool Cams that I got from a dealer in town which comes in two pairs (one for old saws, and one for new saws). The hole in the middle of the Cam is open and slides over the black stem but have different sizes so just pick the ones that fit, they will be the lighter of the two colors (one dark pair and one light pair). I can't remember the exact price but I know it was around $25, maybe a little less, and I can't remember the part number but the guy at the store just called up to Indiana and they figured it out. If you have your saw just look in the parts diagram in the back of the manual.
So, first off you can see the Cam is a little chewed up. This is where I was holding it with vice grip channel locks. I have the small irwin pair which are nice because they have some teeth that can lock into the grooves on the Cam so you don't have to crank down to hard to hold it tight. Whatever you use they need to be skinny enough to work with the dremel. You could also just put it in a vice, but I didn't want to risk over tightening and warping it, or having it too loose, move around and dremeling the Cam side that would eventually be riding against the track.
I just eyeballed the amount that needed to come out, but basically it is halfway, or just bit over, down the side edge that touches the t-track on the guide rail. The easiest way to describe it is to compare the Festool Cams that you get or have with the ones that you are replacing from the guide, you will need to be at least that low to fit under the slot where the Cams sits in the guide. You can see a little indent or cove that goes all the way around the Cam just below the grip, this is where you need to use the dremel bit to eat away, Slowly, very SLOWLY (on a middle rotary speed, not fast not slow) half of the side edge. Use the channel locks to stabilize and the other hand to do the dremeling. I just turned the bit long ways across the face and just cut a decently clean line around and the dove in barely past where the grip plane is. One important thing is to try and make it square to the face, it doesn't matter about the back of the cut.
This isn't the most clear picture, but as you can see it fits into the slots in the guide and allows the Festool Cam to increases the spacing to fit the Festool track. Ultimately, the way I determined if this would work or not was lining up the Cam holes from my saw and the black ones from the guide and noticed that the Festool ones had 1-2mm more, which is just enough to sure up the slop. They take some finesse to get in, you pretty much just have to spin them till they look like it will slide down onto the stem and then rotate it around into the slot.
After all this work you will notice that this is still not perfect, it fits snug with no play to the track but the height of the Festool t-track is taller that the depth of the Dewalt guide slot so it rides nicely laterally but Can, NOT 'does', but can have tilt if you don't have everything supported well. I'm not 100% (maybe 85%) happy with it, but it is a temporary solution until I can talk myself into buying a Festool router or my dewalt dies, which might be a while. Till then...
