"New" Table Saw #4: Zero Clearance Insert

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Blog entry by Jon Parker posted 11-21-2008 05:50 AM 2281 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 3: Top Ready Part 4 of "New" Table Saw series no next part

Kind of slow going here as I design the Table Saw cabinet just the way I want it.

I’ve been trying to find a zero clearance insert for the table saw, but have been unsuccessful since it’s so old and Craftsman has since changed their inserts. I finally found one online, but it was $20 + shipping and handling.

I remember seeing an episode of New Yankee Workshop (one of my favorites) that showed making a zero clearance insert from wood and a flush router bit. So instead I dropped by Lowes and bought a flush router bit for $15 and a piece of 1/4” oak for $3.50 … but now I have a flush router bit – it’s always a good day when you can justify a new tool.

I had to slowly sand it down since the actual width is about 1/32” less than the stock.

This is what I ended up with:

-- Jon | Rigby, Idaho

2 comments so far

View Julian's profile


880 posts in 3490 days

#1 posted 11-21-2008 02:48 PM

Nice job. I started out with a 50’s era craftsman 10 inch saw also. I added balanced pulleys, a link belt, and an incra t-fence to it. It was underpowered but very accurate. I ended up making my own inserts, and stand with dust collection also. It sure was a heavy saw.

-- Julian, Park Forest, IL

View brianinpa's profile


1812 posts in 3687 days

#2 posted 11-22-2008 05:23 AM

Looks good. Buying new tools is cool!

-- Brian, Lebanon PA, If you aren’t having fun doing it, find something else to do.

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