I have an old Craftsman with a funky insert. It’s aluminum ( I used to think steel) about 3/32” thick and “D” shaped. I have not found any one anywhere that makes a compatible insert that I can buy. The lip on the insert is so thin that conventional insert instructions just won’t hack it. I took some acrylic and made an attempt at a ZCI: and it worked for a while but was a bear to make. The acrylic is starting to crack and I’ve hacked away some of the...
I picked up my first-ever table saw about three months ago, a Porter-Cable 220 Job site saw. (review) I have been quite happy with it, but it does have a few drawbacks. Probably the biggest, and most often-noted is the funky metal insert next to the blade. This design does not allow for standard zero-clearance inserts to be used, and no one makes one for this saw. Having got some cash from Santa, I have my eye on a dado blade set, but only if I can make an insert to work well wit...
So, after assembling my TS, I was excited to try my first cut with stock blade & stock insert. I was cross-cutting (?) some scrap LVL stock to make sawhorse legs, when one of the cut-offs, slid in between the blade and insert binding the saw blade to make it stop. One of the teeth actually broke off of the blade and was embedded into the off-cut. I re-enacted the scenario in the photo below. My first reaction was, “Oh man, this is why people use zero clearance inserts̶...
I had previously made a proof-of-concept semi-zero-clearance-insert for my table saw. (Yes, partial-zero-clearance makes about much sense as partial zero-emission which I have seen on several vehicles lately. Seriously? My car is zero-emission most of the time, because it’s not running…but I digress.) The other day I decided to get down to doing a “real one.” Same basic method as the previous one. I finally concurred the cut-through by using a smaller blade from my ...
It starts with a plan… I know their not super sophisticated, but with a few 1” pin nails to help reinforce the glue joint, they feel pretty solid. I’ve had this stack dado for a while now, but haven’t had need of it till now…so I had to make an auxillary fence and a ZCI Here’s the set up for cutting the lap joints first lap joint gluing up the drawers… I really need to get some more clamps…. I like using the paper t...
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