|Project by rivox1||posted 05-08-2013 06:10 PM||2477 views||11 times favorited||12 comments|
I wanted a ZCI for my new R4512, but before spending $30 on a store-bought one, I decided to try it and build one myself.
I was inspired by another Jock to make this ZCI. I just made a couple small modifications to his design. The ZCI is made out of MDF.
The plate that came with the saw had a snug fit, so all I did was cut The MDF to rough size, then stick the original plate with double sided tape to the MDF and trace it with a bottom bearing straight router bit. As you can see on the main picture I made a small mistake on the front of it, but functionality-wise it’s perfect.
The new ZCI didn’t have enough clearance underneath to sit on top of the blade, so using a flat top bit in the plunge router made a groove large enough to accommodate the blade.
I used a drill press and Forstner bits to make the finger hole and the holes for the table plate supports to fit. After making sure that the ZCI sat perfectly level with the table, I gave it a few passes through the thickness planer to make sure it was perfectly flush with the table.
In the picture it seems as if there is a gap, but the table saw has a rounded lip that makes it look this way, the fit is actually quite snug.
When it was time to make the blade slot I took the riving knife off; however, I wanted to use the knife that came with the saw, so after making the blade slot, I made it a bit longer using a jigsaw to accommodate the existing riving knife.
Start to finish it took me about 45 minutes to complete. The cost of the materials was probably around $0.38 (I came up with this figure by calculating that I paid $15 for the MDF and it has enough material to make around 40 of these. 14/40=0.375) So If I know anything about finances, spending $0.38 beats spending $30 to get the same result any day of the week!
I’ll be re-making this one to avoid the mistakes I made, and I will be making some more for 45 degree cuts, as well as my dado cuts!
As always, questions, comments, and constructive criticisms are always welcome!
Thanks for looking!
-- Cheers and Safe Woodworking!