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Zero clearance insert

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Forum topic by Vern Leonard posted 08-18-2016 01:40 PM 415 views 0 times favorited 6 replies Add to Favorites Watch
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Vern Leonard

3 posts in 2080 days


08-18-2016 01:40 PM

I am a long time lurker at this site. I recently purchased a new rigid table saw r4512. This is a major upgrade for me. It was a beast to move and assemble by myself but doable. My first task was to make some zero clearance inserts. The plate is very thin so I opted to use some 3/16 thick white board from home depot and still had to mill about.020 off the edges to fit flush. First one is done with the exception of extending the slot for the riving knife.


6 replies so far

View Planeman40's profile

Planeman40

805 posts in 2227 days


#1 posted 08-18-2016 02:18 PM

I recently made a zero clearance insert for my Hammer sliding table saw out of aluminum as the shape of the hole around the saw blade was of an irregular shape and long and not very wide. Works (and looks) beautifully! Aluminum can be easily cut with a carbide saw blade. I just made the insert with no saw slot, lowered the saw blade all the way, installed the aluminum insert, then started the saw and slowly raised the blade to cut the saw slot.

Planeman

-- Always remember: It is a mathematical certainty that half the people in this country are below average in intelligence!

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FlushTrimBit

6 posts in 125 days


#2 posted 08-18-2016 02:59 PM

How did you mill it, with a bandsaw?

View Vern Leonard's profile

Vern Leonard

3 posts in 2080 days


#3 posted 08-18-2016 03:15 PM

I should have said thickness instead of edge. Which I did on my router table.

I cut the shape close on the band saw then taped the original throat plate to the new one and used a flush trim router bit and the router table to get the finished size.

View skatefriday's profile

skatefriday

380 posts in 948 days


#4 posted 08-18-2016 04:07 PM



I should have said thickness instead of edge. Which I did on my router table.

I cut the shape close on the band saw then taped the original throat plate to the new one and used a flush trim router bit and the router table to get the finished size.

- Vern Leonard

Bingo. A jigsaw works for the rough cut also if you don’t have a bandsaw.

View runswithscissors's profile

runswithscissors

2192 posts in 1491 days


#5 posted 08-19-2016 12:23 AM

Easy way to extend the slot for the riving knife: reinstall the original throat plate; flip the ZCI end for end; move the fence over so the blade comes up through the ZCI blade slot; finish the cut.

-- I admit to being an adrenaline junky; fortunately, I'm very easily frightened

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Rick M

7929 posts in 1846 days


#6 posted 08-19-2016 09:23 PM

Good job on the inserts. I always thought it was dumb they have rounded ends. I suppose that is to prevent corners from catching but still a PITA.

-- http://thewoodknack.blogspot.com/

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