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The "I'm Not Worthy" Project Log #6: Zero Clearance.... Not NSA Approved!!!

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Blog entry by DIYaholic posted 02-02-2014 07:55 PM 1268 reads 0 times favorited 32 comments Add to Favorites Watch
« Part 5: Grinding Out a Turning Tool Sharpening Station Part 6 of The "I'm Not Worthy" Project Log series Part 7: Cross Cut Sled - Winging It!!! »

The NSA denied my Gub’ment Security Clearance….
So, I now have Zero-Clearance!!!

I’ve had my C’man 113 Contractor TS for a while now. I never bothered making Zero-Clearance inserts. There was no point, my skills do not warrant such attention to cut quality. Plus, I was using the cr@ppy used blades that came with the purchase of the used saw. That is until I recently upgraded. I went with the Irwin Marples line of blades, Rip, Crosscut & Combination. Not necessarily premium blades, but better than I had.

Now that I had “decent” blades it was time to decommission the OEM metal insert and tighten things up around the blade. I had some scrap 1/2” Birch ply, from that Big Blue Box store, that I used. Definitely not an artsy build, but a necessary one. Pretty simple build, as most already know…

Pattern Routing the Blanks:

Then I rabbeted the underside at the router table, used a forstner bit & a round over bit, for the finger hole.
My feeble mind forgot to take pictures….

I did scratch my head for a while. NO! Not because of dandruff!!!
Coming up with the rear hold down perplexed me for a moment or two.

Rear Hold Down Solution:

Pre-install Routed Underside Blade Clearance:

Installed Insert, Minus Clearance Slot:

Time to Raise the Bar, err Blade!!!:

Less is More, When it comes to blade clearance!!!

I now have 4 inserts, one for each blade and one for the Dado Stack.
I do need to apply wax and do the clearance cuts….

The Whole Famn Damily!!!

I do have an issue with the insert & blade upgrades….
My poor skills have yet another excuse removed!!!

Please surf the web carefully,
Remember, the NSA is watching!!!

Thanks for looking in….

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?



32 comments so far

View RussellAP's profile

RussellAP

2954 posts in 952 days


#1 posted 02-02-2014 08:04 PM

You could wax them, but you don’t have to. Be very careful bringing a blade up through those to cut the blade slot. Especially the dado. I can send you pictures of my left hand pinky when it got turned into hamburger one day because I didn’t clamp a board to the top of the insert, but instead held a 4×4 over it.
And don’t think you can over power it, you can’t.

Still cant bend that finger. Never will it looks like.

-- A positive attitude will take you much further than positive thinking ever will.

View Gary's profile

Gary

7286 posts in 2098 days


#2 posted 02-02-2014 08:07 PM

Nice work, Randy. Now ya gotta find something to make so you can use them

-- Gary, DeKalb Texas only 4 miles from the mill

View DIYaholic's profile

DIYaholic

13620 posts in 1340 days


#3 posted 02-02-2014 08:11 PM

Russell,
No pictures needed….
1) I hate bloody mangled messes (especially my own)!!!
2) Lesson learned from other’s mistakes!

I already raised the blade on one & used a clamped board as a backer/hold down….

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View DIYaholic's profile

DIYaholic

13620 posts in 1340 days


#4 posted 02-02-2014 08:12 PM

Gary,
Thanks for the kudos!
That is another “downside” to the upgrade….
Gonna need to be productive!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

#5 posted 02-02-2014 08:16 PM

A word of advice… Make sure the retaining nut on the blade shaft won’t hit if you raise the blade too high. I know that was adjustable on some craftsman saws….

These look great. Also, for thought, you can make / buy some kerf splitters or whatever they’re called to keep wood from binding on the back side of the blade when you’re sawing…..

-- Practice does not make perfect. Only perfect practice makes perfect. Vince Lombardi

View patron's profile

patron

13059 posts in 2006 days


#6 posted 02-02-2014 08:21 PM

looks like you are moving away from procrastination son
with all these new posts

these are nice

do please hold them down securely
(i put my fence over them close to the blade
or clamp a board next to that path)
saw a post here recently
where he just held it down with a block of wood by hand
got hurt from that

let them look
might teach them something

if they are watching you
i might be able to feed my dog
without looking over my shoulder
and arrested for not asking for permission

edit :
seems everyone was writing same as me
hold those suckers down good first !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View lightcs1776's profile

lightcs1776

3683 posts in 319 days


#7 posted 02-02-2014 08:30 PM

Nice idea for rear hold down solution. I’ve been using mine without one. Now. I can add on.

-- Chris ** If there must be trouble, let it be in my day, that my child may have peace. — Tom Paine **

View JL7's profile

JL7

7219 posts in 1630 days


#8 posted 02-02-2014 08:42 PM

Well done….agree that the rear down idea is a good one…..will have to copy that myself. If you haven’t already, make one for your miter saw as well…..you won’t regret it…....

Like Lucas said also, a splitter is a good idea. I have a Micro Jig splitter I need to install on mine…..

Carry on….

-- Jeff - I have not failed. I've just found 10,002 ways that won't work.

View DIYaholic's profile

DIYaholic

13620 posts in 1340 days


#9 posted 02-02-2014 08:43 PM

Lucas,
I may add a splitter, but one is not necessary at this point….
I use the OEM blade guard/splitter/pawl attachment, when doing through cuts.
If I find thin/narrow cuts are too inconvenient, then I’ll add one.

Dad,
Thanks for noticing my attempt at procrastination abatement!!!
Russell had the same safety warning….
Already addressed and implemented!!!

Thanks for caring!!!

Chris,
I appreciate the sentiments!
I contemplated a metal hold down, but couldn’t find suitable material in the shop….
Hence the head scratching!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View DIYaholic's profile

DIYaholic

13620 posts in 1340 days


#10 posted 02-02-2014 08:49 PM

Jeff,
I’m flattered….
”Imitation is….”

The SCMS Z-Clearance is high on my list….
I have some hard board, taped down right now, as a make shift one!!!

A splitter is a future possibility….

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View patron's profile

patron

13059 posts in 2006 days


#11 posted 02-02-2014 08:56 PM

watch the head scratching too

looks like you got a line of stitches already from that
and i’m guessing that little cap
is to keep what hair you got left

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View DIYaholic's profile

DIYaholic

13620 posts in 1340 days


#12 posted 02-02-2014 09:04 PM

David,
Oh, I’ve had stitches in my head, but not head scratching or baseball related.
We were playing indoor soccer in the dorm lobby, back in college….
My head went through the phone booth glass!!!
Blood EVERYWHERE, except in my head!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View Mainiac Matt 's profile

Mainiac Matt

4046 posts in 994 days


#13 posted 02-02-2014 09:10 PM

Nice job Randy….

I still have my C-man 113 stored on the other side of the basement (yah, my wife if bugging me to post it on CL) and even though I cut blanks for ZCIs years ago I never finished them. When I stumbled upon my $100 Jet cabinet saw (which as you know, required a LOT of TLC) I decided to splurge and buy a Leecraft phenolic ZCI. What a huge difference it made. Wish I finished making them for the C-man long ago.

Cleaner cuts, better DC, potentially safer….. what’s not to love about that.

Your dungeon is coming along nicely. Looking forward to seeing what you make down there next.

-- Pine is fine, but Oak's no joke!

View DIYaholic's profile

DIYaholic

13620 posts in 1340 days


#14 posted 02-02-2014 09:29 PM

Thanks, Matt.

You should sell the saw….
Then put that money towards another NEEDED tool.
We ALWAYS need a new tool!!!

I know that the next thing I make….
Will be a MESS!!! Just don’t know what the project will be!

Speaking of better DC….
I purchased some magnetic vent covers, for forced hot air vent covers….
Using it to seal up some of the large openings, hopefully improving DC.
There will still be plenty of openings, to allow proper air flow & not starve the DC of air.
Time will tell….

Cut to shape for the back of TS:

Front “Tilt Lever Lock” Opening:

Front “Tilt Lever Lock” Cover:

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View lightcs1776's profile

lightcs1776

3683 posts in 319 days


#15 posted 02-02-2014 11:08 PM

Hey Randy, where did you find the magnetic covers?

-- Chris ** If there must be trouble, let it be in my day, that my child may have peace. — Tom Paine **

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