zero clearance dado damage

What is a zero clearance dado insert? Do you buy an insert for every possible blade set width?

-- I would drink a river of the kool aid before I took the smallest sip of the tea...

Absolutely dangerous. If the blade catches that plate on the up-cut it will throw it at you like a boomerang, but harder and faster. If you can’t return it, find a way to secure the back of it down. I’m surprised you were able to cut it with that tab missing.

Also curious, zero clearance ‘dado” insert? How does that work with different sizes?

-- I'll grow up when ketchup bottle farts stop being funny.

Its the plate that covers the blade on a table saw and I bough it with an Olshun 8” stacked dado set to cut 5/8 inch dados for some decorative garden boxes Im building for my wife.

-- "It is amazing what you can accomplish when you dont care who gets the credit"

I assume that it is only “zero clearance ” when I use the width that originally I cut the plate with (or larger) but I assume it is still okay if I use it with a smaller width (assuming I secure the backside) THANKS probably should have checked the forum BEFORE I cut the insert, could have saved money and stayed safe.

-- "It is amazing what you can accomplish when you dont care who gets the credit"

I’ve never heard of trying to go for zero clearance with a dado cutter. There are a nearly infinite number of possible width and height setups and the zero cllearance part never lasts past the first couple of setups.

As far as that tab goes, I make my own inserts and just drop them into the throat. I’ve never lost one in over 30 years of making sawdust. – lol

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

Now I get it… it’s meant for that one particular width makes sense. Still, I’m surprised it didn’t flip back at you when raising the blade up through it. I may be wrong, but I’d figure out a way to secure it. But I’ve never had a problem with rip-out when cutting dados, since the blade is at such a low angle. If the regular plate has a wide enough opening, maybe try a few test cuts to see if the zero clearance is really necessary.

-- I'll grow up when ketchup bottle farts stop being funny.

have to concur with sawkerf, the only way you can really catch a throat plate of that nature is to start the saw past the height allowable for the blade in the insert, which well you’d notice, if you raise a saw into a plate it should cut through the insert before it can catch.

However a good sharp dado set of decent quality should aleviate the need for a zero clearance plate.

-- The mark of a good carpenter is not how few mistakes he makes, but rather how well he fixes them.

You could always try gluing/screwing a small piece of wood/plastic on the bottom of the insert to replace the tab. The tab doesn’t have to be able to withstand the entire force of the motor spinning the blade (the original tab isn’t that strong), just enough force to allow the blade to cut the insert if it comes in contact.

TedW, I would hope when he initially cut the ZCI he had something clamped over the top of it to keep it in place, which would have prevented it from kicking up. I wouldn’t ever try to cut a new ZCI without it being clamped down.

It’s probably fine to use now if you don’t go to the full height you used to cut the insert, but I would feel better adding some sort of stop in the front just in case.

-- John

Buying plate inserts is similarly as absurd as a woodworker buying push sticks and feather boards. You’re a woodworker. Make them!

-- "The way to make a small fortune in woodworking- start with a large one"

I’m with Miles, I make my own. The zero clearance inserts for the new Unisaw are over $50each. I can buy 1/2” corian for that much and make dozens in just a few hours.

-- If the old masters had power tools, they would have used them. So get off your damn High Horse.

“Buying plate inserts is similarly as absurd as a woodworker buying push sticks and feather boards. You’re a woodworker. Make them!”

That’s actually a bit of an absurd statement… but in any event, for the OP, I’d contact Woodcraft and explain what happened, I am sure they would offer a refund or exchange.

-- John, BC, Canada

I’m with Miles and Scot. I got a set of ZCI’s and dado inserts with my BT3100. the saw was at least 10 years old when I bought it and I’ve had it for two years….. none of them have ever been cut. I use them as a template to make wooden ZCI’s and use the original metal insert when needed, usually for dado work.

nwbusa, why would you think it absurd to make your own push sticks and inserts if you are a wood worker?

-- Improvise.... Adapt...... Overcome!

I don’t thinks it’s absurd to make one’s own ZCIs… I make mine too. I think it’s a bit silly to state that because we are woodworkers, we should make all of our wood items ourselves. That’s like telling a metal worker to make his own rivets, because they are made of metal. Sometimes, it makes sense to buy vs. make your own, even when the product in question is made of wood.

-- John, BC, Canada

I clamped it down on both sides. I want to make zero clearance inserts but Im not sure how. Any suggestions? I have a Ridgid R4512 and it has a 1/8 ” lip. Any how too videos for that?

-- "It is amazing what you can accomplish when you dont care who gets the credit"

Use plexiglass or lexan.