|Project by Oldtool||posted 08-05-2013 12:00 AM||3473 views||12 times favorited||12 comments|
I have a very inexpensive table-top table saw, with an insert stamped from thin sheet metal, which it flexes or bows down with any weight on it, not to mention the permanent 5/8” wide opening around the blade, making this saw difficult & somewhat dangerous to use on small, narrow, or short parts.
In order to fill some of my afternoon, I decided to improve this situation by making a zero clearance insert. The first problem is the fact that the insert mounting pads don’t allow for any material thicker than 1/16”, see photo number 3.
I decided to just strengthen this plate, using it for mounting again, but with an epoxied 3/4 oak attachment, as the table offered no other option for mounting of anything thicker. I first needed cut the additional insert material to fit the opening, and then create a rabbit for the existing insert.
After using epoxy to adhere the oak to the thin plate, I needed to find & use extra long screws to secure the plate in place over the blade, which when taken completely down was only 1/8” below the table top, as shown in photo #2. I secured it at this height using two squeeze clamps, photo number 5, and slowly ran the blade up through the oak.
With the new assembly now secured with the original short screws, you can see in photo #1 that this created a good flat and zero clearance opening for delicate work. As far as flex, there is none, and I’m more comfortable with the closed up 5/8” opening.
I hope this helps any others that are suffering with a similar situation on a saw of this type.
Thanks, and I’ll be glad to answer any questions.
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