Zero Clearance inserts revisited.

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Project by Routerisstillmyname posted 07-02-2010 09:03 PM 3221 views 9 times favorited 2 comments Add to Favorites Watch

This time I’m using a ¾ ply to make few of these. Not that I need more of these since I use each ZCI on both sides for two different saw blades, But I just wanted to have a little fun trying a different technique while procrastinating on real projects ;-)

Any heaux, I use the already made handy ZC instead of the original throat plate to draw the pattern and for router pattern cut using flush trim bit. Trimmed the extra using poor man’s band saw. Once that was complete, I measured the exact dept for the insert and subtract that from the ply and rabbited the rest using a straight bit to make the rabbet all around the insert. (Look ma, no need for adjustment screws) Rabbeting router bit would have been handy but for some reason, I can’t talk my self into buying one.

The next step is using the 8 inch dado set to make the two underside grooves that are over 1/4 thick. This of course is not necessary if you have a table saw that let’s the 10 inch saw blade go way down below the insert. But unfortunately with Ridgid table saws that’s not an option hence the extra step with dado or couple of 8 inch blades. (Not sure if Ridgid remedied that with the now discontinued granite top). Then out goes the dado stack and in goes the blade/s that I will be suing with this ZCI. Touch of paint or stain or sealant ………I use each ZCI with two saw blades of different size so it saves time making more of these.

So, do I prefer this method better than my original?
Absolutely not! It takes longer to make ZCI this way but if you don’t have material that is exact thickness or real close and you don’t feel like using adjustable screws than this is the way to go. the point is there is no reason to pay for a ZCI.

-- Router è ancora il mio nome.

2 comments so far

View miles125's profile


2180 posts in 4002 days

#1 posted 07-02-2010 09:22 PM

Not sure i follow why you’re making them 3/4” thick.???

-- "The way to make a small fortune in woodworking- start with a large one"

View Routerisstillmyname's profile


763 posts in 3506 days

#2 posted 07-02-2010 09:26 PM

I don’t make them ¾ thick. this is the only one. As I said it can be done using ¾ if you don’t have anything else around the shop or don’t feel like messing with leveling screws.

-- Router è ancora il mio nome.

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