Tablesaw Help Needed

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Forum topic by Packrat44 posted 06-08-2011 11:33 PM 1321 views 1 time favorited 5 replies Add to Favorites Watch
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4 posts in 2539 days

06-08-2011 11:33 PM

Does anyone have a suggestion for a zero clearance table insert for a Delta 36-540 bench top table saw. The existing insert has a wide dado type opening and it is hazardous with narrow stock. The provided insert is a thin sheet steel metal plate with one rolled edge to provide rigidity and is supported front and back with a small ledge and along the left side with a small ledge. The right side has no support, only a beveled edge. Ideas or suggestions are welcome—-It has to be thin and ridgid. It is a jobsite saw that I use since it is so nice and light and gives me reasonable accuracy for trimwork and fabrication. Thanks so much.

5 replies so far

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5654 posts in 2808 days

#1 posted 06-08-2011 11:47 PM

I made one out of 1/4” hardboard for a Craftsman with a similar shape. Bevel the edge to match the saw. It worked fine for a while. Then I got tired of messing with it and upgraded to a Jet contractor saw.
Good luck

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5708 posts in 3227 days

#2 posted 06-08-2011 11:49 PM

You are most likely going to have to DIY one, or possibly search on Amazon to see if anyone is selling ZCTPs for that saw…

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Kent Shepherd

2718 posts in 3281 days

#3 posted 06-09-2011 12:02 AM

If you can find it, make one from phenolic to fit your saw. It comes in different thicknesses. It can be cut and milled with woodworking tools, although it is very hard—that is why it is a good choice. There are certainly cheaper alternatives, but they don’t last as long. If you don’t use the saw much, that may not matter to you.

I have made inserts out of scrap wood, MDF, plywood, etc, but being in production, I wasn’t happy with them.
I got tired of replacing them.


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75 posts in 3388 days

#4 posted 06-09-2011 12:35 AM

I have made zci from masonite and 1/2” plywood. Use the metal insert as the pattern to cut out a number of replacements. I milled a area away around the edge of the plywood to make clearence to fit the hole and sit on the support edges. take a little to much off and then build up with masking tape. It would be a good idea to insert a splitter behind the blade as well….. phil

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4 posts in 2539 days

#5 posted 06-09-2011 05:56 AM

Thanks to everyone who was kind enough to respond——-you’ve given me several possiible ideas that I can try. The major stumbling block appears to be the thiness of the stock insert—-it’s I would guess about 16 gauge steel and the rolled edge gives it ridgity——I was hoping that there was a like insert out there that someone had found and used that would close up that dado sized opening at the blade. I’ll try your ideas and see how thin I can go with the suggested materials——will let you know what works and what doesn’t——actually, you all will probably know by the amount of bad language coming from my end of the world. Thanks again.

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