Zero Clearance Insert for Ryobi BTS15

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Project by SuperCubber posted 01-11-2015 09:13 PM 1707 views 0 times favorited 3 comments Add to Favorites Watch

What a pain in the butt it was to figure out a way to make this work well. After about 1000 Google searches, I cobbled together this mishmash of ideas.

Basically, it’s a piece of 3/32 plywood, sanded down to the required thickness (approximately 5/64, or so), and then glued to a piece of hardwood that fits the rest of the opening. The edges of the hardwood look a little messy, because my first attempt was drilling, routing and chiseling the waste from the original poplar piece. That proved way too flimsy for actual use, thus I pursued the plywood solution. To insure a snug fit, I added a screw on each end that can be tightened, or loosened for a nice fit. I also took a page out of Mathias Wandel’s book and added a nail to the back. This isn’t as critical as it was in his application, but doesn’t hurt any.

I realize this isn’t very helpful for folks without this saw, but hopefully the next guy that Google’s “Ryboi BTS15 Zero Clearance Insert” will have another option to look at!

Comments, critiques, other ideas always welcome.

-- Joe | Spartanburg, SC | "To give anything less than your best is to sacrafice the gift." - Steve Prefontaine

3 comments so far

View Cantputjamontoast's profile


416 posts in 2849 days

#1 posted 01-11-2015 09:36 PM

I own that saw thank you

-- "Not skilled enough to wipe jam on toast!"

View SuperCubber's profile


828 posts in 1701 days

#2 posted 01-11-2015 10:28 PM

Awesome! You’re very welcome!

-- Joe | Spartanburg, SC | "To give anything less than your best is to sacrafice the gift." - Steve Prefontaine

View shadowmatrix's profile


1 post in 310 days

#3 posted 12-15-2015 04:18 AM

Thanks for the post. Looks like the saw that I have. And could find no other info on zero clearance for it. cheers.

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