Dewalt Miter Saw Zero Clearance Insert

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Project by pintodeluxe posted 1295 days ago 8532 views 20 times favorited 22 comments Add to Favorites Watch

I finally made a zero clearance throat plate for my Dewalt 12” chop saw. I don’t know why I never did this before. A scrap of 1/4” mdf worked well. All it took was two layers of tape on the aluminum rim under the insert to bring it flush with the table.
I always used a plywood fixture that screwed to the miter saw if I needed a splinter-free cut. That worked fine if you were only making square 90 degree cuts. This zero clearance insert moves with the table – just like the factory insert- so you can cut at any angle.
The limitation is that it will only prevent splintering on three sides. You can still get some minor imperfections on the edge of the board against the fence. Still, an improvement over my old fixture for most cuts.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

22 comments so far

View Rob Vicelli's profile

Rob Vicelli

96 posts in 1323 days

#1 posted 1295 days ago

Great Idea!! I will be borrowing that one.

-- Rob V

View AttainableApex's profile


338 posts in 1464 days

#2 posted 1295 days ago

ya me to, always thought about making one, if it was possible. but now it is i gues

-- Ben L

View spamfilterman's profile


147 posts in 1653 days

#3 posted 1295 days ago

Well done, I need to do the same to my Dewalt too

View Canadian Woodworks's profile

Canadian Woodworks

604 posts in 1701 days

#4 posted 1295 days ago

I need to do this also

-- Paul Lemiski, Ontario Canada, Custom Wooden Rocking chairs and tables

View devann's profile


1735 posts in 1324 days

#5 posted 1295 days ago

If you clamp a piece to the fence you’ll hav no tearout at the fence and you won’t need to turn on your laser ether. The cut at the fence shows were the blade is cutting.

-- Darrell, making more sawdust than I know what to do with

View devann's profile


1735 posts in 1324 days

#6 posted 1295 days ago

I used to screw a piece to the fence but now I clamp it so I can reposition the MRF/MDO when I need an angle. Make sure and have it a little long to start with because you use it up fast once you start flipping back and forth cutting angles.

-- Darrell, making more sawdust than I know what to do with

View Steven H's profile

Steven H

1114 posts in 1691 days

#7 posted 1295 days ago

I wish they made insert from heavy metal, it would stay flat.

View Harry_Ch's profile


63 posts in 1307 days

#8 posted 1295 days ago

Thanks for the idea. Got a new 12” slider and was going to use the full fixture backing but will give this a try.

-- Deeds not Words.

View Ken90712's profile


14878 posts in 1820 days

#9 posted 1295 days ago

I just made 4 fo them for my table saw this weekend as well. Nice work.

-- Ken, "Everyday above ground is a good day!"

View rance's profile


4130 posts in 1792 days

#10 posted 1295 days ago

Pinto, I’ve been meaning to do this too. Maybe this will motivate me. :) Thanks for posting.

@ Steven H – Right before you change your blade or get it sharpened, fashion a thick aluminum insert, cut it, then send your blade off to get sharpened. Actually, that sounds like a great idea. Well… I think a nice thick wooden one would be just fine.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View jm64's profile


36 posts in 1313 days

#11 posted 1295 days ago

Great idea. Think I’ll put that to use.

-- Joe, Cumming, GA

View ratchet's profile


1286 posts in 2418 days

#12 posted 1295 days ago

I say Brilliant! Or at least very clever…thanks.

View bobber52's profile


2 posts in 1626 days

#13 posted 1295 days ago

Great idea. I’ll be making some of these this weekend. Thanks for sharing.

-- Bob, Burnsville, NC

View Sierras's profile


22 posts in 1403 days

#14 posted 1295 days ago

I was cross cutting yesterday on my Dewalt and cussing the tear out . Know what I am doing today. Thanks

View Don Johnson's profile

Don Johnson

611 posts in 1412 days

#15 posted 1295 days ago

Looks a good idea – and your adjustable left side back guide is pristine (unlike mine – which I forgot to move when doing a bevel cut LOL )

-- Don, Somerset UK,

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