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Thicker zero clearance inserts

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Project by rmoore posted 03-29-2011 04:14 AM 2561 views 11 times favorited 14 comments Add to Favorites Watch

I have an old Craftsman table saw with a very thin throat plate. It is only 1/4 inch thick. I tried making a ZCI from 1/4 inch hardboard before but it was so light I was afraid it would fly out at me someday. I came up with the idea to put 3/4 inch plywood underneath the 1/4 inch plywood. It just had to be smaller than the top opening. The good thing about it being thicker is I can also have a splitter in the main ZCI.
The main one was a little harder to make. My 10 inch blade would not go down far enough to clear the ZCI before I made the cut. I had to put a circular saw blade on it and raise it up, then switch to the 10 inch blade.
The finger holes also make it easier to pull them out when swapping. The original didn’t even have a finger hole.

-- The more I learn, the more I realize I don't know. Ron, Crossville Tn





14 comments so far

View cwdance1's profile

cwdance1

1143 posts in 1913 days


#1 posted 03-29-2011 04:17 AM

Very good design. Do you have any trouble with your height adjustment?
That would be my only worry.

View rmoore's profile

rmoore

313 posts in 1289 days


#2 posted 03-29-2011 04:26 AM

cwdance1, Are you referring to maximum height? I haven’t checked it but I’m sure it will when it hits the arbor or the thicker part of my dadoe blade. Still better than stock.

-- The more I learn, the more I realize I don't know. Ron, Crossville Tn

View kiefer's profile

kiefer

3070 posts in 1321 days


#3 posted 03-29-2011 04:38 AM

looks like a good plate idea
as to the arbor hitting could you not cut out a relive in that area ?

kiefer

-- Kiefer 松

View Viking's profile

Viking

857 posts in 1849 days


#4 posted 03-29-2011 04:41 AM

Rmoore;

Think we have the same Craftsman (113.299120) saw that we use as our backup table saw and want to add a ZCI to it. Thanks for sharing this. My original steel insert has a spring clip at the away end to keep it in the table. Did you cut your 3/4” for a friction fit or ??

We also just bought the Delta T-2 fence but not yet installed. How was the fence rail installation for you?

Thanks

-- Rick Gustafson - Lost Creek Ranch - Colorado County, Texas

View Russ's profile

Russ

356 posts in 1731 days


#5 posted 03-29-2011 05:16 AM

That’s a great idea. I’m in the same situation with my Rockwell. I’ll have to try this with existing ZCI.

-- Russ

View rmoore's profile

rmoore

313 posts in 1289 days


#6 posted 03-29-2011 05:38 AM

kiefer, Thanks for the idea. I started to doubt myself.

Viking, Not sure of the exact # right now of my table saw. My original insert had two clips but one was broken when I bought it. I put the 1/4 inch in the slot then reached underneath and traced the edges so I would know what shape to cut the 3/4 inch.

I think you will love the Delta fence! ( I wondered if anyone would notice that in the picture.) I love mine! I had to drill new holes in the table. The bolts that hold the extension tables on keep the rails from mounting flush but a washer took care of that. I plan to add wooden extension tables on soon so I’ll fix that then.

-- The more I learn, the more I realize I don't know. Ron, Crossville Tn

View rmoore's profile

rmoore

313 posts in 1289 days


#7 posted 03-29-2011 05:47 AM

Viking, Hersh did a blog on installing a Delta t-2 fence on a Craftsman table saw. It is called “Table Saw Rebuild”. Lots of pictures and details on installing the fence. link

-- The more I learn, the more I realize I don't know. Ron, Crossville Tn

View Viking's profile

Viking

857 posts in 1849 days


#8 posted 03-29-2011 06:23 AM

Rmoore;

Thanks for the information.

Good Luck!

-- Rick Gustafson - Lost Creek Ranch - Colorado County, Texas

View steliart's profile

steliart

1807 posts in 1342 days


#9 posted 03-29-2011 03:03 PM

nice solution
well done

-- Stelios L.A. Stavrinides: - I am not so rich to buy cheap tools, but... necessity is the mother of inventions - http://www.steliart.com --

View RTim's profile

RTim

60 posts in 1346 days


#10 posted 03-29-2011 03:04 PM

I have a similar saw. Great idea for a ZCI…gotta make some for myself now. Thanks for posting.

-- Tim from MA -- "Well done is better than well said." - Benjamin Franlin

View devann's profile

devann

1735 posts in 1346 days


#11 posted 03-29-2011 04:00 PM

I made new ZCI for my 10” TS because somone had modifided the factory made one to accept a dado. I uesd 3/4” plywood and was worried about those flying out and hitting me. I made clips from a metal framing stud to screw the insert to. I had trouble keeping them in place to drill the holes in them so I shot them with spray paint to mark the clip location. I change inserts when I change angles.

The tablesaw is an old Boice Crane model 4500

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

View Hersh's profile

Hersh

106 posts in 2369 days


#12 posted 03-29-2011 06:25 PM

Rmoore,
Great idea. I will give this insert idea a try. You have done a good job on your TS. I noticed you have seen my blog about my TS rebuild. Thanks for looking. I hope the information helps other LJ’s to upgrade their old Craftsman TS.

Again, thanks for your ZCI idea.

-- Hersh from Port Angeles, WA - Gotta Complete That Project!

View MasterSergeant's profile

MasterSergeant

1288 posts in 1342 days


#13 posted 03-29-2011 06:49 PM

I have the what sounds like the same saw. I have/had the exact same problems making my ZCI. I just finished mine yesterday and we had THE SAME SOLUTION, pretty cool!

Great minds think alike!!

-- Kelly, woodworker under construction

View thelt's profile

thelt

620 posts in 2033 days


#14 posted 03-31-2011 01:57 PM

I have the Craftsmam model 315.228310. I’ve got the same problem with making a ZCI. This sheds a little light on the matter. Anybody else have this model saw?

-- When asked what I did to make life worthwhile in my lifetime....I can respond with a great deal of pride and satisfaction, "I served a career in the United States Navy."

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