Dewalt Miter Saw Zero Clearance Insert

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Project by pintodeluxe posted 02-09-2011 04:29 AM 15329 views 22 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 2112 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 2253 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 2442 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

702 posts in 2490 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


2199 posts in 2113 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


2199 posts in 2113 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

1117 posts in 2480 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 2096 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


16864 posts in 2609 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


4243 posts in 2581 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 2103 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


1389 posts in 3207 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 2415 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


35 posts in 2192 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

650 posts in 2201 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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