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Table Saw Zero Clearance Inserts

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Forum topic by Roger posted 04-28-2016 01:09 AM 1217 views 2 times favorited 31 replies Add to Favorites Watch
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Roger

19867 posts in 2266 days


04-28-2016 01:09 AM

Topic tags/keywords: zero clearance inserts

Almost the first thing I did was to make some zero clearance inserts for Bertha. (me new tablesaw).


Afterwards, I made the first insert a perfect fit, then used it, with a piece of masking tape around the outside to make the other 9 inserts a skoosh larger.

After double stick taping then together 2 at a time to get the basic shape with the bandsaw cutting near the pencil line, then fit them, one at a time by shaping them on my belt sander. I worked at it a little at a time by marking where it needed shaving. Just a few back n forth trips to the belt sander did the trick.



Thnx for lookin and good/bad/ugly’s are read and appreciated. (not the ugly’s)

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. Kentuk55@yahoo.com


31 replies so far

View Jim Jakosh's profile

Jim Jakosh

17143 posts in 2567 days


#1 posted 04-28-2016 01:24 AM

Very fine job of making those inserts. you will love them compared to that wide open one that comes with it.

way to go, Roger!!!!!!!!!!!!!!!

Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View Joe Lyddon's profile

Joe Lyddon

9432 posts in 3514 days


#2 posted 04-28-2016 01:25 AM

COOL way to get things off to a good start!!

Why didn’t you use the Original taped to the first one that was close, and use a router with flush trim/pattern bit to get a perfect copy… Then use it for the rest of them?

Just curious…

You have a nice supply that should last a long time…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View matt garcia's profile

matt garcia

1877 posts in 3133 days


#3 posted 04-28-2016 01:29 AM

New tablesaw? I’m jealous!! Nice job on the inserts!!! But I do have one question. Exactly how much is a “skoosh”?

-- Matt Garcia Wannabe Period Furniture Maker, Houston TX

View Nubsnstubs's profile

Nubsnstubs

826 posts in 1192 days


#4 posted 04-28-2016 01:30 AM

Same thoughts as Joe…..... Jerry (in Tucson)

-- Jerry (in Tucson)

View Jim Bertelson's profile

Jim Bertelson

3962 posts in 2626 days


#5 posted 04-28-2016 01:34 AM

I have used the band saw and sander trick (I use a 12” disk sander) to make good repetitive curved surfaces. And just recently, at that. But it involve some small parts and it seemed to be pretty effortless. But I have made a bunch of ZCI’s just as Joe describes, using the original insert as the pattern. Hard to beat.

So, it’s just a matter of what you are doing and what you are used to, I guess.

But no debate, ZCI’s are the way to go…................

-- Jim, Anchorage Alaska

View kdc68's profile

kdc68

2526 posts in 1738 days


#6 posted 04-28-2016 01:43 AM

That’s what I need to do. Having multiples is a great idea…..Thnx for sharing !

-- Measure "at least" twice and cut once

View Roger's profile

Roger

19867 posts in 2266 days


#7 posted 04-28-2016 01:47 AM

Hey folks. Thnx for the looks and comments. I didn’t do the pattern bit thing because of the “nibs/tits” on the sides of the factory inserts. I thought that might be a problem with a pattern bit. Either way, probably would have came out to the same finish.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. Kentuk55@yahoo.com

View Grumpy's profile

Grumpy

21562 posts in 3313 days


#8 posted 04-28-2016 01:58 AM

Well done Roger. That should keep Bertha happy.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View doubleDD's profile (online now)

doubleDD

5221 posts in 1505 days


#9 posted 04-28-2016 02:02 AM

A must for the table saw. Safety first.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Jerry's profile

Jerry

1767 posts in 1110 days


#10 posted 04-28-2016 03:09 AM

Niiice! I bought mine. You do great work Roger, but you need to keep that beard away from the saw blade, heh heh :-)

-- There are good ships and there are wood ships, the ships that sail the sea, but the best ships are friendships and may they always be. http://geraldlhunsucker.com/

View Joe Lyddon's profile

Joe Lyddon

9432 posts in 3514 days


#11 posted 04-28-2016 04:17 AM

Yep, final results are probably the same… except one is Faster than the other & copies are Dead On duplicates. :)

After making the First one to fit & is perfect, it could have been used with the router process & would have been much much easier, faster, & more accurate.

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View oldnovice's profile

oldnovice

5723 posts in 2829 days


#12 posted 04-28-2016 04:41 AM

That is a quite a few of zero clearance inserts Roger!
Nice work for a shop addition.

I only have a couple and I make mine with my router table using the factory original as a template.

-- "I never met a board I didn't like!"

View Boxguy's profile

Boxguy

2173 posts in 1729 days


#13 posted 04-28-2016 06:50 AM

Roger, there are four tabs in the throat of your table saw. For some mysterious reason table saw manufacturers seem unwilling to machine these tabs to an exact size and instead want to leave them as rough castings. I have found that it is easier to fix the tabs instead of having adjusting screws in all of your inserts. The fix is easy. Choose your material for the insert…I use high molecular density plastic (the white heavy stuff). Put a dab of JB Weld on each of the four tabs, top that with a piece of wax paper or aluminium foil, (so you don’t glue in the insert) then press the insert into the throat until it is dead level with the table. A flat board will do this trick. Let the glue dry over night. Now, every time you make an new insert it will fit exactly. If you louse the alignment up just grind away some of the J B Weld and try the process again.

-- Big Al in IN

View Lenny's profile

Lenny

1487 posts in 2989 days


#14 posted 04-28-2016 09:52 AM

What inserts? All I see is glare off of that shiny table saw.

-- On the eighth day God was back in His woodworking shop! Lenny, East Providence, RI

View Roger's profile

Roger

19867 posts in 2266 days


#15 posted 04-28-2016 11:39 AM

Thnx folks.

BigAl: that’s a good idea.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. Kentuk55@yahoo.com

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