Scroll saw zero clearance table top

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Project by jfk4032 posted 09-14-2012 01:49 AM 6836 views 13 times favorited 5 comments Add to Favorites Watch

I saw this table top insert used by a master intarsia artist who inspired me to try intarsia. When cutting very small pieces this zero clearance table top makes it easier and safer to manuever the pieces around the blade and not worry about the large gap on the Hegner tabletop which accommodates the table swivel to catch small pieces while cutting.

It’s quite simple yet works like a charm. I simply cut a piece of plywood scrap to the desired shape with a little overhang beyond the Hegner table. I attached three runners to “lock” the table top onto the existing metal table and then used multiple layers of metal ductwork tape to build up one side which was a little loose and made it a perfectly snug fit. This metal tape also helped to center the blade alley to slide effectively back and forth when installing and then taking off the table top. This tape buildup can be seen in the closeup shot in the last picture. I had to keep the thickness of the runners thin enough to not catch on the blade clamp jig when sliding table into position.

I finished the table top with Beall buffing system to make it easier to cut on. You can see the difference between the unbuffed bottom surface and the top surface in the pictures.

-- ---Joel; Central MD...rookie empter nester and getting back into woodworking!

5 comments so far

View Monte Pittman's profile

Monte Pittman

29871 posts in 2482 days

#1 posted 09-14-2012 01:52 AM

Nice job. Looking forward to more projects in the future.

-- Nature created it, I just assemble it.

View Hawaiilad's profile


3279 posts in 3165 days

#2 posted 09-14-2012 03:42 AM

Hi Joel, I have made tables like this for my Hegners. Do you have a problem threading the blade through the small hole up to the top blade holder? And where did you purchase the tubes for your blades

-- Larry in Hawaii,

View Ken90712's profile


17575 posts in 3333 days

#3 posted 09-14-2012 09:18 AM

Wll done, look fwd to seeing some work off this.

-- Ken, "Everyday above ground is a good day!"

View jfk4032's profile


365 posts in 2671 days

#4 posted 09-14-2012 10:48 AM

Hi Larry,

Dont’ have a clue yet on threading the blades since I just finished the table top and haven’t cut anything on it other than a couple of small pieces to test out the table…I haven’t tried changing blades yet.

The tubes were purchased at: They work great, won’t break and I put labels on the outside to identify which blades are in them. Any standard soda cap will fit them, so if you want to color code them you can do that. I use a different color for blade I’m using at that time. I made tube holders to go around 3 sides of the Hegner stand and attached those with several rare earth magnets.

-- ---Joel; Central MD...rookie empter nester and getting back into woodworking!

View stefang's profile


15947 posts in 3478 days

#5 posted 09-14-2012 08:00 PM

Great idea Joel. I just have a a cut-off platter for my zero clearance top which I use carpet tape to hold down. Your top is a lot better with the slip fit for easy installation and removal. I will have to try it. Thanks for sharing.

-- Mike, an American living in Norway.

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