|Project by DaveTPilot||posted 02-17-2011 12:41 AM||5980 views||4 times favorited||15 comments|
I was in serious need of a zero clearance insert for my new Grizzly G0715P. I ordered one from Grizzly but they were back ordered by several months? So I had to make one.
The stock insert is only 1/8” thick so plywood or mdf alone was out of the question. I had some 3/8” ABS plastic that I could rabbet down to 1/8” but that would be too flimsy as well. I decided to use a combination of the plastic and 1/2” mdf. So, I cut them a little over-sized and glued them together with Gorilla Poly glue.
I drilled a hole in each end of a piece of 12” scrap. One hole held a Shapie and the other, a nail. On the table top I taped a piece of paper and traced the shape of the table saw inlet by using the nail as a guide. I used the paper template to make a plywood template on the band saw and cleaned it up with the spindle sander until it fit with good clearance. You don’t want that to fit too tightly.
I attached the template to the plastic side of the insert blank with double-sided tape. This served as my guide template for my Daisy Pin Router. Making multiple passes, I continued to raise the router bit until it started cutting into the underside of the plastic. I cut the plastic until approximately 1/8” was left.
I replaced the plywood template with the stock insert and trimmed it to a perfect fit. I love that Daisy Pin Router! I also used it to raise the bit up to make all the holes, except for the leveler holes. I drilled those on the drill press.
Cutting the kerf was a little tricky because the blade is in the way if you try to install the insert. I had to elevate the shop made insert above the installed stock insert with some 2×2’s. I used the fence to hold the alignment on the right side of the blade and a 2×4 clamped in place and pressed against the left side. Another 2×4 pressed on the top with one hand left the other hand to raise the blade slowly. You just need to cut enough of a kerf to install the insert then you can raise it all the way up using the fence to hold it in place. I then needed to flip the insert over so I could cut the kerf long enough to use the splitter. (I think I need to do a video for this) :)
Some white primer and red Krylon Fusion plastics paint finished it up nicely. (You don’t need the primer but the red doesn’t come out as bright painting directly on the black plastic.)
I also made a zero clearance insert for my dado set up for 1/2” plywood.
PS I just received an email today from Grizzly that the insert has been shipped…it took three months.
-- How valuable is time to a person who spends his disparaging the beliefs of others? --David Berthelette www.pilotwoodworks.com