zero clearance insert

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Forum topic by drpdrp posted 03-14-2014 04:52 PM 1030 views 0 times favorited 3 replies Add to Favorites Watch
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150 posts in 2009 days

03-14-2014 04:52 PM

3 replies so far

View paxorion's profile


1107 posts in 2009 days

#1 posted 03-14-2014 05:04 PM

I posed a forum topic about this new and improved Porter Cable saw yesterday:

I haven’t seen the saw in person yet, but I suspect it will be in line with other saws in that class: a thin sheet metal insert between 1/16” and 1/8”. It may be difficult to make a dependable ZCI using plywood or MDF, but a composite material may be more viable.

-- paxorion

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Jim Finn

2647 posts in 2885 days

#2 posted 03-16-2014 04:35 PM

I made mine of 3/8” MDF and it has lasted seven years so far. Looks like that saw has a very thin insert so I would try aluminum. With aluminum you can cut to shape and then secure with the fence and cut the slot by raising the saw blade as it is running. Many blades will cut aluminum with no damage to them.

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150 posts in 2009 days

#3 posted 03-23-2014 09:07 AM

So I whipped one together out of 1/4 plywood and it… kinda worked? I used it for a set of cuts that I “needed” the zero tolerance-ness- but afterwards removed it because it felt unsafe. It kind of wants to blow up and out- I am going to try gluing some bracing in underneath to see if that helps.

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