Reply by bondogaposis

I don’t have that exact saw but my stock insert is 1/8” sheet metal. The way I make mine is to cut a piece of MDF a bit larger than the insert. Then I laminate formica to both sides w/ contact cement. I then trace the insert on to the laminated MDF and rough cut close to the line w/ a bandsaw. I then tape the the stock insert to the laminated MDF with double sided tape, make sure it is stuck good. Then I put a flush trim bit in the router table and carefully adjust the height so that only the bearing rides on the steel while the blade trims the ZC insert to exact shape. I then remove the steel insert and put a rabbit bit into the router table and dial in the thickness so that the ZCI has a rabbet on the underside and the top sits flush to the saw top. Then when I am happy that the insert fits into the saw nicely, I lower the blade and pop in the ZCI and bring the rip fence over the top of the ZCI. Make sure that the rip fence is not sitting over the blade, then turn on the saw and slowly raise the blade and you will have a nice durable ZCI. I don’t worry about the clip in the back or the screw in the front for that matter. In many years I have never had one get thrown at me. Some guys put a rare earth magnet in there to hold it, but I have never had a problem leaving that off.

-- Bondo Gaposis