“This molding cutter will not fit my insert for the table saw,” I says to me. So I says, “Let’s make a new one.”
“Use some MDF and trace the Zero Clearance Insert you bought from Lee Craft,” says I to me. “yes, and good folk they were.”
“Trace the thickness needed” says I.
Okay, enough of that weird self talk. Time for the coping saw, having ripped MDF to thickness.
Trace the parts of the old ZCI so that it will fit into the table saw. These parts will need to be drilled out. Originally, I was going to grind them out, but having taken a break for work at UPS, I came up with using my forstener bits instead. Absolutely amazing how time away from something allows the gift of insight to operate.
Yup, needs some drilling & a bit of grinding to fit in.
This is what an old drill press looks like!
An adjustable screw to hold it tight when inserted
We have a fit, though it is a bit sloppy at the end, and I drilled the finger hold on the wrong side, so I drilled a second one.
Okay, now I was a bit sloppy using the 1 1/4” bit to drill the clearance hole, but it fit and raising the spinning blade slowly showed that it was just about spot on.
A thin wall on the top section
Disasterous results, blow out. It was all going so well and then my finger felt on ouch like being hit with a little bat, while a big bang/thwack sound happened.
The insert destroyed…the cutter head is blue because I was using chalk to help drill out the hole for it.
Maybe some runners for support next time?
Okay, so I ran the pine wood through the cutter slowly, and raised it bit by bit on each pass. As the blade got higher, there was more chatter on the piece, and at one point I was it move a bit. I should have used my feather board which would have made this safer and easier. But still, why did this happen?
A. Wall on the wood too thin?
B. The knot?
C. The wiggle I saw earlier in the wood?
D. Dull cutter?
E. Bad insert?
F. Raising the blade too much at once and taking to big a bite?
G. Other thoughts?
Love to have some folks help and advice here on what happened and on how to prevent the blow out and strengthen the insert. The last picture is my next plan, unless there are other suggestions.
-- I came, I was conquered, I was born again. ἵνα ὦσιν ἓν