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Zero clearance insert

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Project by Alonso posted 07-21-2009 06:19 AM 5222 views 10 times favorited 13 comments Add to Favorites Watch

This is my first completed project, (well actually fully completed, since I also builded my workbench, mitter saw bench, a bench tool system and a box joint jig, but I haven’t apply any protective finish on them, this is why I call this one the first complete project LMAO.

I want it to have some zero clearance inserts for my new Ridgid R4511, and after watching some videos and reading a few tutorials I decided to start with them. Unfortunatelly at that time I didn’t had the right materials (at first I used 1/2” plywood) and the flush bit for the router that I used wasn’t long enough, I end up gouging my original insert, ( see picture #2). I replace the 1/2” plywood with some 15/32”

At this stage I dind’t knew what to do, after doing some research I found out that SC has some inserts (model 35831) that fit perfectly on my R4511, with that being said I went to my local Woodcraft and got one for $50.00, and also I got a longer flush trim router bit. Now I was back on track.

The rest you can judge by looking to the pictures. I used some polyurathane protective gel, and some little tiny screws that I found on the deepest place of my garage are now the leveling screws for the inserts to sit flush with the top. Total = less than $75 (including the insert replacement from SC)

Any comments will be highly appreciated.

At the same time I would like to ask something. How do I cut the extra part for the riving knife or the blade protector?

Thanks

Alonso

-- The things I make may be for others, but how I make them is for me.





13 comments so far

View a1Jim's profile

a1Jim

112089 posts in 2231 days


#1 posted 07-21-2009 06:26 AM

super job

-- http://artisticwoodstudio.com Custom furniture

View Alonso's profile

Alonso

946 posts in 1892 days


#2 posted 07-21-2009 06:42 AM

Yeah I read that before but I couldn’t find an effective and safely way to enlarge the opening to allow access for the Riving knife he does not specified how he made them so I guess I will contact PurpLev on this one. thanks

-- The things I make may be for others, but how I make them is for me.

View Routerisstillmyname's profile

Routerisstillmyname

703 posts in 2163 days


#3 posted 07-21-2009 07:59 AM

Good job.
Depending on where you live, wooden on some poly inserts can warp to some degree. You may want to check those from time to time just to be safe.
Here in Houston, I keep most small things inside due to extreme heat n humidity.

-- Router è ancora il mio nome.

View Beginningwoodworker's profile

Beginningwoodworker

13341 posts in 2327 days


#4 posted 07-21-2009 12:06 PM

Nice job.

-- CJIII Future cabinetmaker

View David65's profile

David65

190 posts in 1939 days


#5 posted 07-21-2009 04:23 PM

Very nice I did the same thing in gouging my first router table insert because the thickness was off on the bearing.

-- David '65

View Karson's profile

Karson

34876 posts in 3055 days


#6 posted 07-21-2009 04:27 PM

The inserts look great. Nice job. I need to make a few for my table saw. My current insert is cast iron so I can’t use it for dados.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †

View PurpLev's profile

PurpLev

8476 posts in 2303 days


#7 posted 07-21-2009 04:42 PM

those look great! one of the best, easiest, cheapest upgrades a saw can have!

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View PurpLev's profile

PurpLev

8476 posts in 2303 days


#8 posted 07-21-2009 04:46 PM

I PM’ed Alonso – but though others might benefit from this as well, so:

I cut the opening for the riving knife using a jigsaw – safe no danger operation – and no kick backs.

this also leaves the back of the riving knife in tact, and not split in 2 like factory supplied plates are, which makes their back less rigid.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View mtkate's profile

mtkate

2049 posts in 1979 days


#9 posted 07-21-2009 06:44 PM

So, doing this in plywood is considered relatively safe? Awhile back I did not have a dado insert and made one out of plywood – and was very paranoid when using it. I finally found a metal insert.

View ChuckM's profile

ChuckM

501 posts in 2320 days


#10 posted 07-22-2009 02:25 AM

In addition to PurpLev’s way of doing it, there’s another simple and more accurate way which I and some others used to create the slot for the splitter (mine is a Rigid TS 3665 and doesn’t have the riving knife):

1) Place your shop-made zero clearance insert on the tablesaw and align the fence on the tablesaw so the blade will cut exactly the same slot that you have cut for the blade

2) Go ahead and cut the insert until the new slot meets the old slot – now you have a long slot running from one end

3) To give the rigidity that PurpLev talked about, glue a short piece of hardwood (same thickness of your slot / blade) into slot at the end (the short piece should not hinder the up and down movement of the riving knife)

That was how I cut the full slot and installed my splitter accurately and quickly. Another advantage was I could use 1/2” plywood and not worry about the blade not sitting down below the insert when I needed to raise the blade to create the slot.

If the above is not clear, email me and I’ll send you a pic.

P.S. If you still have the receipt, you may able to return the $50 insert to Woodcraft now that you have made so many shop-made inserts.

-- The time I enjoy wasting is not time wasted

View BTKS's profile

BTKS

1967 posts in 2118 days


#11 posted 07-31-2009 11:44 PM

Alonso,
Just finished making my first insert for my Steel City Saw, Am posting the details on a new project. I’ll have details there. Thanks for the inspiration and getting up my gumption to make this very necessary accessory.
BTKS

-- "Man's ingenuity has outrun his intelligence" (Joseph Wood Krutch)

View dlux's profile

dlux

54 posts in 2087 days


#12 posted 09-02-2009 06:36 AM

Very nice, and much cheaper than the ones at Woodcraft!

View bigike's profile

bigike

4031 posts in 1942 days


#13 posted 11-15-2009 03:34 PM

nice ZCI it looks good with the blade coming through it

-- Ike, Big Daddies Woodshop, http://www.icombadaniels@yahoo.com

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