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Cheap Table Saw Inserts

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Forum topic by juniorjock posted 02-28-2008 05:56 PM 1538 views 1 time favorited 11 replies Add to Favorites Watch
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juniorjock

1930 posts in 2421 days


02-28-2008 05:56 PM

Topic tags/keywords: jig tip tablesaw

I saw this on AmericanWoodworker. It’s a great idea.

Commercially made zero-clearance inserts cost about $20. I make my own for less than $3 from 3/8-in.-thick polyethylene cutting boards, which are flat and rigid. A 14-in. x 17-in. cutting board ($10 at a discount department store) yields four inserts. After rough-sawing the blank on my bandsaw, I attach the saw’s insert with double-faced tape. Then I rout the blank to final size using a flush-trim bit. I drill 11/64-in. pilot holes and install the adjustment screws, which are 3/8-in.-long #10-24 Allen-head set screws (about 40 cents each at a hardware store). Raising the blade through the polyethylene to cut the zero-clearance slot leaves plastic curls around the edge. They’re easily removed by filing or sanding.


11 replies so far

View Scott Bryan's profile

Scott Bryan

27251 posts in 2478 days


#1 posted 02-28-2008 06:39 PM

Nice tip. I will have to keep this in mind the next time I replace my zero clearance plate.

-- Challenges are what make life interesting; overcoming them is what makes life meaningful- Joshua Marine

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juniorjock

1930 posts in 2421 days


#2 posted 02-28-2008 06:55 PM

The way I see it, with the cost this low, I could make a different insert for all the basic dado set ups (1/4, 3/8, 1/2, etc.) The dado insert that came with my Grizzly G0575 table saw is a “one size fits all” and there’s way to much space when using one of the smaller dado set ups.

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John Gray

2370 posts in 2541 days


#3 posted 02-28-2008 07:16 PM

Thanks for the post I’m in the process of making some inserts too.

-- Only the Shadow knows....................

View DavidH's profile

DavidH

508 posts in 2399 days


#4 posted 02-28-2008 07:38 PM

Thanks for this, a table saw book I have suggests making them out of MDF but I like this idea too.

-- David - Houston, Texas. (http://www.justsquareenough.com/)

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Dano

222 posts in 2688 days


#5 posted 02-29-2008 02:27 AM

neat idea, thanks, guess I need to make a trip to Wally World…

-- Dan in Central Oklahoma, Able to turn good wood into saw dust in the blink of an eye!

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teenagewoodworker

2727 posts in 2424 days


#6 posted 02-29-2008 02:37 AM

that’s a good idea. i probably would have bee the first person to buy them at someplace like Rockler. so you’ve just saved me a load of money. thank you.

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juniorjock

1930 posts in 2421 days


#7 posted 02-29-2008 02:48 AM

Yes it sounds like a great idea, but please note that I haven’t actually tried this yet. But I plan to sometime this weekend and I’ll let everyone know how it does. Heck, for the money, how could you go wrong?

View rikkor's profile

rikkor

11295 posts in 2530 days


#8 posted 02-29-2008 04:52 PM

Great tip JJ.

View ChicoWoodnut's profile

ChicoWoodnut

904 posts in 2471 days


#9 posted 03-01-2008 05:54 AM

I make mine exactly that way using luan plywood. Rout them out an put set screws in. It takes about 15 minutes to make one.

-- Scott - Chico California http://chicowoodnut.home.comcast.net

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tomd

1758 posts in 2426 days


#10 posted 03-01-2008 06:07 AM

I’m with Chico, I use luan too, I usually make up about 6 at a time and throw them away as they wear out, I also make them for my bandsaw, and my router table. The router table you can make several sizes of bit hole sizes.

-- Tom D

View Suz's profile

Suz

51 posts in 2412 days


#11 posted 03-02-2008 01:10 PM

I’m lucky enough that I can make my ZCI’s out of 1/2” MDF.

-- Jim

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