Zero Clerarence Insert

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Project by JoeyG posted 11-23-2011 03:39 PM 2525 views 0 times favorited 11 comments Add to Favorites Watch
Zero Clerarence Insert
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I am working on a series of nine boxes and have lots and lots of miter keys to do. I was just putting a piece of 1/4 plywood over my table saw and using that as a zero clearance so the thin strips would not fall through. Well my plywood final got to small so I started searching the shop for a piece of lumber that wasn’t going to become a Christmas Gift. All I had were two 1X3X16 inch pieces of mahogany. I glued them up, resawed them to 5/16, fine tuned the thickness with my jointer and now I have a really pretty table saw. I wanted to save these pieces for something special because they were really pretty, so now I have 2 inserts and I get to look at em every time I use my saw. I may have to make more of my jigs out of pretty cut offs. I like looking at the nice wood in my shop instead of giving it all away.

Thanks for taking a look. Have a safe holiday, and wish me luck to not turn my turkey into saw dust. LOL

-- JoeyG ~~~

11 comments so far

View CharlieM1958's profile


16274 posts in 4184 days

#1 posted 11-23-2011 04:12 PM

Now THAT’s a high-end ZCI!

-- Charlie M. "Woodworking - patience = firewood"

View TexasNick's profile


68 posts in 2434 days

#2 posted 11-23-2011 04:13 PM

Nice insert Joey. I made one a couple of months ago out of some scrap Cherry. After a couple of weeks, I went to take it out and it had expanded to the point of requiring a hammer to get it out. I hope you don’t have the same problem. I replaced mine with an insert made out of 3/8” Lexan. It worked perfectly.

-- Experience: What you have left after you've lost everything else.

View Routerisstillmyname's profile


763 posts in 3475 days

#3 posted 11-23-2011 05:02 PM

Make sure that blade is 100% aligned in every which way before you cut that mahogany.

-- Router รจ ancora il mio nome.

View MasterSergeant's profile


1361 posts in 2654 days

#4 posted 11-23-2011 05:47 PM


-- Kelly, woodworker under construction

View lanwater's profile


3111 posts in 2900 days

#5 posted 11-23-2011 10:54 PM

Mahogony insert. Cool.

No spliter or riving knife?

-- Abbas, Castro Valley, CA

View JoeyG's profile


1275 posts in 2591 days

#6 posted 11-23-2011 11:21 PM

I had it off to use my sled. Just hadn’t got around to putting it back on when I clicked this picture. It gets in the way when I use my miter key jig.

-- JoeyG ~~~

View kiefer's profile


5618 posts in 2633 days

#7 posted 11-24-2011 04:08 AM

My question is don’t you tilt yuor blade at times ?
I have about 10 inserts and 10 or so spares ( not as nice as yours ) for the different blades I use and same for tilting applications , that is also the reason I build my double bottom sled .
Nice wood for the inserts ( Mahogany ) I love the look and I may have to upgrade .

Thanks for the look Kiefer

-- Kiefer

View JoeyG's profile


1275 posts in 2591 days

#8 posted 11-24-2011 02:47 PM

HAPPY THANKSGIVINGS!!!!!!!!!!!!!!!!!

haha. Yes Kiefer I do make angle cuts on my table saw. I mainly use three. 90, 07, 45. The 07 degree cut is for my boxes with the angle sides. I made two inserts. when I made this one. The mahogany piece I used was 1 inch thick so I got two inserts when I resawed it. I have two blades, 3 angles, and I will be adding another bottom to my sled. Thanks for the idea.

I never expected this to make it to the Daily Top Three. I almost didn’t post it, but I think it looks really good and decided to share it. It was really cool to wake up the the top 3. One more thing to be grateful for on this day of gratefulness.

Have a wonderful and safe holiday,


-- JoeyG ~~~

View BigFoot Products Canada's profile

BigFoot Products Canada

711 posts in 3359 days

#9 posted 11-24-2011 04:54 PM

Nice job.. I cheat and cut my inserts out of acrylic for my table and band saw… with my laser..:)

View SeaFarin's profile


69 posts in 2278 days

#10 posted 02-03-2012 07:26 AM

You’ve inspired me to make my own! I think I have same table saw and fence.

-- I'm Chuck and I wood not chuck wood cause I keep finding uses for it!

View JoeyG's profile


1275 posts in 2591 days

#11 posted 02-03-2012 01:32 PM

Hi SeaFarin, I’m Joey,

I like the saw, The fence can be a bit touchy. I am looking forward to upgrading, but it does what I need it to as long as I keep a eye on it. I will be looking forward to seeing a picture of what you come up with for a insert.

-- JoeyG ~~~

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