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Zero Clearance Insert Questions

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Forum topic by TopamaxSurvivor posted 04-06-2011 08:15 AM 1747 views 0 times favorited 34 replies Add to Favorites Watch
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TopamaxSurvivor

14796 posts in 2342 days


04-06-2011 08:15 AM

Topic tags/keywords: zero clearance insert question brown hard board

I made a ZCI for my 3/4 dado blade. The raw unadjusted board sets .010” below the table. Will this be an issue that causes problems?

I made it using what I call hard board. It is the brown stuff that is slick on one side and rough on the other. Will this absorb moisture from the atmosphere and change with the seasons?

It feels solid in the saw, but is this material really suitable for ZCI?

I made it tight enough that it stays solid without any clips. Just a good tight end to end friction fit.

Yeah, yeah, I know; it doesn’t fit!! Just put it back for the pics ;-)

-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence


34 replies so far

View patron's profile

patron

13064 posts in 2007 days


#1 posted 04-06-2011 08:33 AM

i made one out of particle board years ago
it still works just fine

i layered tape at the ledges
(on the ZCI itself)
to shim it where needed
so the work doesn’t catch
on the cutout lip
as it goes by

the nice thing about doing it yourself
you always know a guy
that can make another one
if needed

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

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TopamaxSurvivor

14796 posts in 2342 days


#2 posted 04-06-2011 09:07 AM

Nice to know the material will be fine. I have a full sheet I got for free ;-)) With the .010” edge, I can just catch my finger nail running across it. That is the only issue, catching the material?

If I need to adjust it, I thought I would wax the hole really well and bed it with epoxy like we do for rifle actions in a stock. It will fit perfect than ;-))

I ;need to make a few more for 1/4 and 1/2 and maybe 3/8 for the dado. I need to make some for other blades too if I’m going to get out of the rough carpentry mode into WW ;-))

-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View bluekingfisher's profile

bluekingfisher

1043 posts in 1646 days


#3 posted 04-06-2011 09:15 AM

Good job Bob, the material will be fine.

Having the insert below the table may cause you a problem though as the stock may catch on the table as you push it through the blade. Not an issue at the front but if anything, it should be at least level or even proud of the table insert outfeed end.

Patron is right, a little tape will shim it out ok and may even provide some adhesion to prevent the insert from rattling.

-- No one plans to fail, they just, just fail to plan

View devann's profile

devann

1735 posts in 1358 days


#4 posted 04-06-2011 09:22 AM

Looks good, ditto above about shimming. You may want to consider drilling a finger hole to make it easier to remove once you have a finish fit.

-- Darrell, making more sawdust than I know what to do with

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TopamaxSurvivor

14796 posts in 2342 days


#5 posted 04-06-2011 10:09 AM

It doesn’t rattle. I filed it in and fitted it tight enough to stay put. I will probably make finger holes on the smaller ones, but this one has a 3/4 hole already ;-)) I’ll shim the back so it is even or proud. thx for the critic.

-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View rsladdwoodworks's profile

rsladdwoodworks

311 posts in 1835 days


#6 posted 04-06-2011 10:19 AM

I use hard bored for mine and they work fine i do not use clips and so fare they work good for 4year’s

-- Robert Laddusaw and no I am not smarter then a fifth grader ( and no I canot spell so if it is a problem don't read it ))

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TopamaxSurvivor

14796 posts in 2342 days


#7 posted 04-06-2011 10:23 AM

Thanks Robert, that is good news ;-) Are yours fit tight or a bit lose just setting in the hole?

-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View stefang's profile

stefang

13104 posts in 2000 days


#8 posted 04-06-2011 11:55 AM

Good work on the insert Bob. The tape suggested David will get you flush with the top.

-- Mike, an American living in Norway.

View Don Johnson's profile

Don Johnson

613 posts in 1447 days


#9 posted 04-06-2011 12:25 PM

I’m puzzled! The insert shown doesn’t seem to be ‘zero clearance’ !

Or was it a test piece for the outer shape?

And may I also ask – when raising the blade on a virgin insert to cut a zero clearance slot, how is the insert held down – with a sacrificial piece of stock clamped across the table on top of the insert ?

-- Don, Somerset UK, http://www.donjohnson24.co.uk

View bluekingfisher's profile

bluekingfisher

1043 posts in 1646 days


#10 posted 04-06-2011 01:03 PM

Don, If you don’t mind me butting in, my blade was too tall by about an 1/8” when cranked all the way down so I had to lay the insert on top, ease it up off the front of the blade and slowly drop the insert down using a stick. I should have changed the blade to one of my 9” blades, just never thought about it at the time. My method was not ideal but I have seen it done where the fence of the saw was brought over to cover the right side of the insert (as you look at it from the front) then cranked up. When the fence is clamped down it holds the insert in place

-- No one plans to fail, they just, just fail to plan

View mcase's profile

mcase

438 posts in 1795 days


#11 posted 04-06-2011 01:12 PM

Topa,

In the photo that looks a 1/4” of masonite that just sitting in a 1/4” recess. To keep it from lifting (or worst yet) flying if caught by a raised dado head it may not be a bad idea to tap a screw in from above if possible or finding some way of clipping it from underneath. The old saws with loose inserts were usually 1/2” or better and sat deeply seated in a recess. The thin 1/4” ones were affixed in some way.

View bubinga's profile

bubinga

861 posts in 1334 days


#12 posted 04-06-2011 01:24 PM

I’m puzzled! to i don’t see a ‘zero clearance’ ! insert in the picture

-- E J ------- Always Keep a Firm Grip on Your Tool

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bluekingfisher

1043 posts in 1646 days


#13 posted 04-06-2011 01:30 PM

I think it reads ZCI for a 3/4” dado??

I think the single blade in the photo has confused the matter

-- No one plans to fail, they just, just fail to plan

View HorizontalMike's profile

HorizontalMike

6942 posts in 1580 days


#14 posted 04-06-2011 02:34 PM

QUESTION:
Has anyone laminated hardboard together and planed to thickness when making such an insert?

-- HorizontalMike -- "Woodpeckers understand..."

View Sawkerf's profile

Sawkerf

1730 posts in 1735 days


#15 posted 04-06-2011 02:58 PM

When I was using a Craftsman TS, I made several ZCI’s from 1/4” ply. After shaping them for the throat, I built up the edges with 3-4 layers of duct tape to get them level with the table. I made at least 25 – 30 over the years, and they worked great.

-- Adversity doesn't build character...................it reveals it.

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