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Project by HRLou posted 449 days ago 1190 views 1 time favorited 9 comments Add to Favorites Watch

I’ve just gotten back into woodworking after too long. Part of rebuilding my skills was to remember the lumber rack I had way back when and reconstruct it. Two-by-fours, on edge, lagged into the wall studs with holes drilled every 18 inches or so for the brackets. Brackets are 1/2” ply with a 2-by sandwiched between, and 1/4” bolts through the uprights.

The zero-clearance inserts were a necessity for my old (seriously—’40’s or ‘50’s era) Rockwell tilting-table saw. Instead of going through the expense and headaches of tracking down OEM inserts, it was a quick trip to the Wally World for a large white plastic cutting board and a handful of 1/4” machine screws.

Sexier stuff will be coming later, but I figured instead of just lurking, I should share a little as well.

Thanks for looking!





9 comments so far

View Dallas's profile

Dallas

2686 posts in 989 days


#1 posted 449 days ago

We all have to re-start somewhere. You are doing it right! Carry on.

I like those ZCI’s they look good!

-- Improvise.... Adapt...... Overcome!

View DIYaholic's profile (online now)

DIYaholic

11249 posts in 1177 days


#2 posted 449 days ago

Nice job.

Wanna come over to my shop & make me some ZCI!!! I mean show me how!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View HRLou's profile

HRLou

20 posts in 482 days


#3 posted 449 days ago

Thanks, Dallas. And I appreciate your avatar. I got my start in woodworking in the early 90’s while assigned to the 10th Mountain Division in New York.

DIYaholic, they’re amazingly simple. White plastic cutting board from wherever, use the original throat plate as a pattern and trace it out. The cutting board isn’t the same thickness as the original insert, so I picked up some short screws for “legs” to get it level with the tables. Jigsaw to get to rough shape, file and sandpaper to fit. Put the insert in, mark the support plates from the under side, drill and insert screws—no need to tap for the screws because the plastic is kind of soft. Adjust for level. Wedge insert in place under the fence, raise the blade, and you’re there.

The type of plastic used for the cutting boards is nice and slick, too.

View DIYaholic's profile (online now)

DIYaholic

11249 posts in 1177 days


#4 posted 449 days ago

Good to know. I seriously need to make a few of these. Thanks for the detailed “How-To”!!!

-- Randy-- I may not be good...but I am slow! If good things come to those who wait.... Why is procratination a bad thing?

View JohnMeeley's profile

JohnMeeley

253 posts in 835 days


#5 posted 449 days ago

Great zero clearance plates. To make leveling easier, try through drilling the hole and tapping threads for a set screw. You will be able to level it from above in a snap.
1/2” ply with 5/8” set screw protruding from bottom.

Top View of recessed hex key set screw.

-- "The greatest pleasure in life is doing what others say you cannot do."-Walter Bagehot

View HRLou's profile

HRLou

20 posts in 482 days


#6 posted 448 days ago

Great advice! I’ll give that a shot on the next ones—I still have half a cutting board left!

View Grumpymike's profile

Grumpymike

958 posts in 817 days


#7 posted 448 days ago

John is correct, I do mine this way (after messing with the screws for some time).
I have never used the cutting boards because when I look at them they are alwaysl warped, so I bought a 1/2 sheet of the phonelic (sp??) plastic … ouch! right in the wallet …
I rough them out on the band saw then use a pattern bit for the final trim up.
Drill and tap for 6-32 set screws and your done.
Nice lumber rack, looks like it will take a pretty good load.

-- Grumpy old guy, and lookin' good Doin' it.

View HRLou's profile

HRLou

20 posts in 482 days


#8 posted 448 days ago

Thanks—I don’t have a lot on the rack yet, but it should hold a decent load.

I looked at phenolic at the local Woodcraft, but, yeah—ouch is right!

View HRLou's profile

HRLou

20 posts in 482 days


#9 posted 448 days ago

Holy cow! I just noticed I’m in the daily top 15! Thanks!

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