So I have a cheap, older, table saw. Skilsaw brand. With no intention of upgrading due to space and of course budget.
I had made a zero clearance insert for it awhile back… out of plexi-glass which was maybe not the best choice.
This insert that I made worked very well but it was a pain to make.
During a recent incident in the shop that had to do with a push stick, ripping some thin stock, and a little kickback I no longer have my homemade insert (I always wear my safety goggles). I went to move my fence and there was no more insert under it. It was in about 9 pieces.
So as they don’t make zero clearance inserts for these cheaper model saws I need something else. I will not use plexi-glass again and really to use anything that I cannot see through will be very difficult as I would look through it and use my 1/8” bit in my router to make it fit just perfect. I’ve heard good things about ?lexan?. I am not sure if there is a clear one available.
I have been thinking about just getting a quarter inch piece of something as large the table and just laying it on top of everything. But then I have the issue of my fence and miter gauge not fitting.
Maybe I could take the whole aluminum top off, start over with some heavy duty MDF or Melamine, make it all over and make it bigger. Then I could make a larger opening for my blade and make it easier to change inserts.. Might require a new fence… gees….
Is this a good idea or am I out of my mind?
-- Grant - S/N Dakota