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Made this zero clearance out of hardboard. Nothing new… Used the table saw, band saw and oscillating spindle sander. Works great.
-- Jeremy, Kingwood, Texas
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9 posts in 1464 days
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113830 posts in 2667 days
#1 posted 12-30-2011 01:35 AM
Another good upgrade for your saws ,looks super.
-- http://artisticwoodstudio.com Custom furniture
149 posts in 1955 days
#2 posted 12-30-2011 05:25 AM
Looks OK, but what holds it in? Don’t see any screw. Also, stock throatplate is about 1/2 thick. Wish you had posted a picture of the flip side.
#3 posted 12-30-2011 03:57 PM
When I get around to it I will post a picture of the bottom. Everything is attached from there and the hardboard was laminated up to about 1/2 like you say DYNO360. I know that MDF is the top choice for this, but I didn’t have any when I made it!
4 posts in 1847 days
#4 posted 12-31-2011 03:02 AM
I have this same table saw and have made about 9 inserts for different blade configurations. I used 1/2 ply. In the future I will probably use mdf because a few of them have a minor amount of bow which can be a problem. I roughed it out on the band saw and then used carpet tape to stick the plywood to the stock insert. Then I used a flush trim bit at the router table. The last time I did it it took about 5 min to route 3 of them and they were all exactly the same as the stock insert. I use 4 small screws on the underside of the insert to level it to the height of the table. They are such a perfect fit that there is no need to screw them in. Now I only use the stock insert if I am cutting a bevel.
2012 posts in 2011 days
#5 posted 01-14-2012 10:11 PM
I made this same insert using MDF. I just traced the shape with the original insert and cut it with a scroll saw and sanded smooth. I put it in place, moved the fence over it to hold it down and while running the saw I raised the blade to make the slolt. Now, gravity holds it in place just fine.
-- "Just my opinion, I may be right"
4677 posts in 2138 days
#6 posted 01-22-2013 05:51 PM
I made my ZCIs of MDF also but next time I shall use a different materiel as MDF flex too much.
62 posts in 1045 days
#7 posted 01-22-2013 06:07 PM
Is this the R4512? I know when I made mine, I used some cheap 1/2” sandply from HD. The problem I had was that I has to router out the back where the insert actually sits on the protruding castings and those are only about 1/4” or less from the top. This made the insert fairly fragile and I need to make a new one. Did you have these problems?
5 posts in 1043 days
#8 posted 01-30-2013 10:12 PM
hey darkone, I have the same saw. Trying to make a zero clearance insert is a real problem with that saw because of the leveling screws. Don’t know of a solution but maybe someone will come up with one.
“Money talks. Mine says good-bye!”
-- David Gardner, Natchitoches, LA
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