Ridgid R4512 Zero Clearance Insert

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Project by Lance posted 12-22-2011 04:47 PM 8270 views 30 times favorited 20 comments Add to Favorites Watch

I used MDF, cut the width on the TS and used a jigsaw to cut out the top and bottom, then I used a plunge router for the depth. A lot cheaper than spending $25 on the woodcraft insert!

-- Lance, Hook'em HORNS! ""V""

20 comments so far

View jockmike2's profile


10635 posts in 3281 days

#1 posted 12-22-2011 06:32 PM

I just bought the same saw and am going to be a copycat. Looks great, should work great too. Nice job.

-- (You just have to please the man in the Mirror) Mike from Michigan -

View Paden501's profile


35 posts in 1384 days

#2 posted 12-22-2011 06:33 PM

Nice insert.

Is that the stock riving knife in the photos? I have the craftsman version of this saw (21833) and I swear it has a different knife than what you have photo’d.

View Lance's profile


405 posts in 1560 days

#3 posted 12-22-2011 06:34 PM

It’s stock

-- Lance, Hook'em HORNS! ""V""

View Furnitude's profile


362 posts in 2541 days

#4 posted 12-22-2011 07:12 PM

Nice job. I own this saw also and was about to pay for an insert. I’m curious about why you routed a channel where the blade will go. Do you want to minimize contact with the blade?

-- Mitch, Also blog at

View felkadelic's profile


205 posts in 1574 days

#5 posted 12-23-2011 02:47 AM

Mitch, it was probably to allow him enough clearance to install the insert and raise the blade through

View Lance's profile


405 posts in 1560 days

#6 posted 12-23-2011 05:02 AM

Mitch, that’s right, it was for clearance and I thought it would be better to have less material there for the zero clearance.

-- Lance, Hook'em HORNS! ""V""

View jeff's profile


776 posts in 2499 days

#7 posted 12-23-2011 06:44 AM

nice work.i have the same saw and need a ZCI myself.still developing my woodworking skills so someday i will try to make one.thx for posting.jeff.

-- Jeff,Tucson,Az.

View don1960's profile


214 posts in 1721 days

#8 posted 12-23-2011 06:52 AM

Well, I’m going to copy that also. I just tonight bought that saw at a local outlet tool place
(Tanger Outlets near the Meadows Racetrack in Coraopolis, PA.)

Got it new in a box for $336. A steal, I figure. It’s a ‘blemished’ one. Something about the paint color being off or some such. Heck, at that price it could be painted pink for all I care.

And now I see a great idea for a ZCI. Thanks, Lance,

-- -- Don from PA

View bj383ss's profile


114 posts in 1395 days

#9 posted 12-23-2011 02:11 PM

Nice job Lance. Now that you have made that one, buy you a flush trim bit for your router and you can make as many as you want. I have about 10 of them for mine. One for Dadoes of different sizes, and a couple for different angle cuts. I did not use the stock splitter though I cut a groove in the back in line with the blade and then I installed a hardwood splitter the same width as the blade works better than the stock splitter.



View Lance's profile


405 posts in 1560 days

#10 posted 12-23-2011 05:24 PM

Bret, that’s a great idea, I have a flush trim bit and I plan on making multiple inserts.

-- Lance, Hook'em HORNS! ""V""

View Captainawesome's profile


10 posts in 1054 days

#11 posted 12-19-2012 05:00 PM

Lance, Are the top and bottom two separate pieces?

-- My Nickname is meant to be taken sarcastically... Sean, South Carolina

View pintodeluxe's profile


4085 posts in 1847 days

#12 posted 12-19-2012 05:36 PM

Wow, you really have to cut the support lips thin on that model. The inserts I made for my Jet are much thicker.
Hope they work well for you.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

View Lance's profile


405 posts in 1560 days

#13 posted 12-19-2012 09:09 PM

No, it’s one solid piece of MDF.

-- Lance, Hook'em HORNS! ""V""

View RigorM's profile


2 posts in 1068 days

#14 posted 12-21-2012 06:37 PM

Wow ! great insert.. Just got this saw to replace my old delta shopmaster.. I must admit, i was a bit sad when I saw the thin sides the hold the plate.. good to see that its possible to make a zero insert :-)

I’ll duplicate one with some HDF I have left from my delta’s zero insert I made.

Thanks !

Jeff C.

View Mikeslb's profile


1 post in 1010 days

#15 posted 12-31-2012 03:52 AM

Lance, what do you do with the riving knife locking knob when using a dado set and the home made zero clearance insert, looks like the knob will hit in either position

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