|Project by Dchip||posted 01-13-2011 09:38 PM||2179 views||9 times favorited||7 comments|
There are many different methods for making zero clearance inserts and a lot of saws require very specific dimensions, but I would like to share a very simple method that has worked wonders for me. This will probably only be valuable for those with a need for a 3/8’’ thick insert (My saw is a new portable ridgid).
Essentially, I had a recent epiphany that 1/4’’ +1/8’’ = 3/8’’.
To elaborate, I realized that I could glue some 1/4’’ mdf to 1/8’’ hardboard (both true thicknesses, unlike plywood) and eliminate what’s to me the most difficult step of achieving proper thickness for the insert (I’ve seen people plane down wood to accomplish this, though I imagine it could be subject to movement). After that, all that was left was roughing out the shape on my bandsaw and then a flush trim with the original insert, a finger hole on the drill press, and some finish and a waxing.
*A note on the first picture – In using scraps I didn’t realize until it was too late that one piece of hardboard was actually 3/16’’, and thus I had to knock of 1/16’’ from the bottom border.
This insert should be stable as well as sturdy and I could batch out a number of them in short period of work. I experimented with 3 to start, but will be making enough to cover common blade kerfs, blade angles and dado sizes in the near future.
I hope this proves helpful to some, I welcome any questions/comments you may have.
-- Dan Chiappetta, NYC, http://www.9x7woodworks.com