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Dewalt Miter Saw Zero Clearance Insert

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Project by pintodeluxe posted 02-09-2011 04:29 AM 9407 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.
-Cheers

-- 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

100 posts in 1438 days


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

Great Idea!! I will be borrowing that one.

-- Rob V

View AttainableApex's profile

AttainableApex

338 posts in 1580 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

spamfilterman

147 posts in 1769 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

632 posts in 1817 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 http://www.canadianwoodworks.com

View devann's profile

devann

1735 posts in 1439 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

devann

1735 posts in 1439 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

1114 posts in 1807 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

Harry_Ch

63 posts in 1423 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

Ken90712

15304 posts in 1936 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

rance

4147 posts in 1907 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

jm64

36 posts in 1429 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

ratchet

1304 posts in 2534 days


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

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

View bobber52's profile

bobber52

2 posts in 1741 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

Sierras

27 posts in 1518 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

624 posts in 1527 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, http://www.donjohnson24.co.uk

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