Dewalt Miter Saw Zero Clearance Insert

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Project by pintodeluxe posted 02-09-2011 04:29 AM 11997 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

104 posts in 1731 days

#1 posted 02-09-2011 04:33 AM

Great Idea!! I will be borrowing that one.

-- Rob V

View AttainableApex's profile


342 posts in 1872 days

#2 posted 02-09-2011 05:18 AM

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 2061 days

#3 posted 02-09-2011 05:23 AM

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

View Canadian Woodworks's profile

Canadian Woodworks

687 posts in 2109 days

#4 posted 02-09-2011 05:48 AM

I need to do this also

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

View devann's profile


1915 posts in 1732 days

#5 posted 02-09-2011 06:26 AM

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


1915 posts in 1732 days

#6 posted 02-09-2011 06:31 AM

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

1116 posts in 2099 days

#7 posted 02-09-2011 06:50 AM

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

View Harry_Ch's profile


63 posts in 1715 days

#8 posted 02-09-2011 09:57 AM

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


15847 posts in 2228 days

#9 posted 02-09-2011 11:59 AM

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


4196 posts in 2200 days

#10 posted 02-09-2011 02:25 PM

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 1721 days

#11 posted 02-09-2011 02:27 PM

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

-- Joe, Cumming, GA

View ratchet's profile


1335 posts in 2826 days

#12 posted 02-09-2011 04:11 PM

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

View bobber52's profile


2 posts in 2034 days

#13 posted 02-09-2011 04:49 PM

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

-- Bob, Burnsville, NC

View Sierras's profile


33 posts in 1811 days

#14 posted 02-09-2011 05:30 PM

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

636 posts in 1820 days

#15 posted 02-09-2011 05:48 PM

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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