Bosch ZCI, Dust Hood, & Storage Upgrades

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Project by newTim posted 01-09-2017 05:03 AM 2152 views 2 times favorited 6 comments Add to Favorites Watch

I don’t know why Bosch doesn’t make a zero clearance insert for sale, or just replace the one they include with this saw. It is the only thing about it that doesn’t work well. Oh well, gives me another design opportunity I guess.

I’ve been remodeling my small shop to create more working space and efficiencies. I’m trying to follow the gaze, grab, and go strategy so I reduce the amount of time I spend looking for things. I also wanted to reduce the amount of dust kicked up by the chop saw. You can’t tell by the pictures being black on black and all, but the cabinet is a hollow shell which allows air to flow into the main dust chute as well as the 2” hose. It works okay, but I’m going to close off some of the peg board holes to increase the draft. Still just having an enclosure has helped a lot.

-- tim hill

6 comments so far

View Rich's profile (online now)


3661 posts in 735 days

#1 posted 01-09-2017 05:50 AM

That’s a beautiful setup Tim. Nice to see I’m not the only nut on here with carefully duct taped bricks for weights. Boy, those things sure come in handy in all sorts of ways. I chose silver tape too. Much classier… lol

Anyway, I ran into the same thing with my Makita. I just wound up making a bunch of blanks out of 1/4 inch MDF. Pretty much throw-away items, but they work. Yours looks like you could do the same thing.

-- Half of what we read or hear about finishing is right. We just don’t know which half! — Bob Flexner

View NormG's profile


6252 posts in 3149 days

#2 posted 01-09-2017 06:53 AM

Great idea, well done

-- Norman - I never never make a mistake, I just change the design.

View Lee A. Jesberger's profile

Lee A. Jesberger

6864 posts in 4125 days

#3 posted 01-09-2017 03:00 PM

Good looking space! Nicely done.


-- by Lee A. Jesberger

View pottz's profile


3146 posts in 1130 days

#4 posted 01-09-2017 03:35 PM

nice job tim love what you did,just finished a new miter saw bench and posted last night myself.i have a dewalt chop box and dust is always and issue,i have a hose and 4” duct behind the saw but its still not the best.i agree about the zero clearance problem.i just ordered a replacement from infinity tools made of anodized aluminum with replaceble inserts,you might check it out.

-- sawdust the bigger the pile the bigger my smile-larry,so cal.

View Scheol's profile


13 posts in 1149 days

#5 posted 01-12-2017 06:59 PM

Looks awesome. Can you comment on the way you created the exact profile template of the insert given that the original plastic one is in two parts?

View newTim's profile


611 posts in 3752 days

#6 posted 11-30-2017 03:07 AM

Scheol, sorry I’m just now seeing your question. There are a few ways to create an exact template. One is that I noticed when I spread the existing plate/insert all the way apart a 3/4” wide piece fit perfectly in the slot. With this knowledge, it is a simple task to remove both sides of the metal insert place them on a piece of paper or 1/4” scrap, put a 3/4” piece of wood between them and line up the top and bottom. You can then trace the outline and the drill holes. I took the existing screws to the local Ace Hardware where they have a screw/bolt sizing jig to find the correct size.

Another way is to place both parts of the insert on a printer or copier and again spread them with the 3/4” wood and take a picture/copy of the template. Same technique use for router bases. Hope this helps.

-- tim hill

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