|Forum topic by bluekingfisher||posted 04-04-2011 10:51 PM||1364 views||0 times favorited||11 replies|
04-04-2011 10:51 PM
I needed to make some dados for a project I’m working on, thanks Tom, which require some fairly lenghty cuts. I don’t have the space to run dados on long wide sheets of ply with a tablesaw so I’ll have to take care of them with a router and straight edge.
For the shorter panels I was itching to cut the dados on my TS for the first time. Problem was I didn’t have any throat inserts to use with a 3/4” stack. I figured I needed about 5 inserts to cover all bases, one for 1/4” cuts one for 1/2” one for 3/4” and a couple for zero clearance single blade cutting. I looked at the price for all five, the prices started about £25 each. A lot more than I wanted to pay.
I know a lot of guys make their own from ply and even plastic cutting boards. I has some scrap 10mm MDF, just enough for 4 inserts. I knew they wouldn’t be the required thickness so I would have to shim them out in some way. As it turned out they were about a couple of mil shy of my required thickness so I drilled some holes and counter sunk them, used some #5 13mm brass screws with the sharps points ground off and used them to level the insert with the table top. I reckon the brass won’t do the cast iron support brackets any harm when I adjust the screws as the brass is a tad softer. In the end they turned out pretty well but I was still one insert short. I had another rumage in the garage and found some scraps of “wetwall” sheet. For those of you who may not know what this is, it is used in bathrooms, in my case in the shower cubicle instead of tile. It comes in 8×4 sheets (& 8×3) The scraps were left over from the bathroom I replaced last year. It appears to be made from 10mm MRMDF with a plastic laminate on either side. The decorative side can be any coulour the customer wants, ours happened to be a grey marble but the back side is plain white. Overall the thickness was 12mm thick, I used the tablesaw standard insert as my template and routed it to shape (as with the MDF) on the router table with a top bearing straight cutter.
I had a problem getting the wetwall to stick to the template even with DS tape, it kept sliding off, I guess designed this way to shed the water in the shower. This too would mean it was a real slick surface for sliding stock over. I had to use a couple of screws to hold them in place.
Anyway the inserts fitted perfectly without shimming have a look at the photos and see for yourselves.
The wetwall wasn’t cheap about £150 for a full sheet and £120 for the 8×3 sheet. I figured for that price I conservatively estimated I could get about 60 inserts out of the smaller sheet for about the same price as 5 store bought inserts. I’m just relieved I had the forsight not to throw the scraps away. I have enough left for about another dozen or so should I need more.
I would never need as many as 60 inserts but if I did buy a sheet I would go for a shiny slick bright red. Just a thought.
Has anyone else used some weird and wonderful material to make their inserts with?
-- No one plans to fail, they just, just fail to plan