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Posted on Zero Clearance Insert for Riving Knife

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800 posts in 2072 days

#1 posted 09-11-2012 06:41 PM

I made ZCIs for my R4512 with 1/4” MDF, with a rabbet around the edge so they sit flush in the throat. I tried using a jigsaw to lengthen the slot for the riving knife, but found that to be a little cumbersome. So I tried a few different methods:

(1) I routed out the knife slot on one ZCI with a 1/8” router bit.
(2) I used a standard hand saw to rough cut a knife slot on another ZCI.
(3) I flipped a third ZCI end for end on the table saw, clamped it down, and raised the blade through it again to lengthen the slot (but I don’t think this made a long enough slot).

Honestly I don’t remember which of these methods worked best, but if you find that the jigsaw is a little wonky these may be viable alternatives. Realistically, I don’t think you need the riving knife slot to be perfectly zero-clearance since that isn’t where you’re going to get chip-out, so even a rough slot should suffice as long as it doesn’t reduce the structural integrity of the insert.

-- Dan in Minneapolis, woodworking since 11/11.

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