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Forum topic by Mark Geserick posted 08-08-2007 03:15 PM 1841 views 0 times favorited 6 replies Add to Favorites Watch
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Mark Geserick

35 posts in 4095 days


08-08-2007 03:15 PM

Topic tags/keywords: table saw insert commercial frame with shop made wood

I’M LOOKING FOR THE TYPE OF INSERT THAT ALLOWS YOU TO REPLACE THE CENTER PORTION AROUND THE BLADE WITH SHOP MADE WOODEN ONES. THIS MAKES IS EASY TO MAKE SEVERAL BLANKS AND SIMPLY REPLACE THEM EACH TIME WITH A NEW ONE.

-- Mark, South Jersey


6 replies so far

View GaryK's profile

GaryK

10262 posts in 4133 days


#1 posted 08-08-2007 03:20 PM

I assume you are talking about table saw inserts.

Just take your current insert clamped to a piece of plywood the thinkness of your insert and use a router bit with a bearing to cut flush around you insert.

Using 1/2 plywood will usually be a little under flush, so I just glue little pieces of wood in the corners and sand them until the insert is flush.

After that just use a dovetail router bit and cut a groove for your insert.

No need to buy one.

But if you do here’s one: http://www.onlinetoolreviews.com/reviews/betterleytrucut.htm

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Hawgnutz's profile

Hawgnutz

526 posts in 4221 days


#2 posted 08-08-2007 04:24 PM

I simply use 1/2” MDF. It is much smoother than plywod and does not splinter as much. If you have an odd-width insert, like my Ridgid (3/8”), simply use a planer to get the desired thickness.

I rough trim it using my old insert, then use my flush trim router bit to make the final cut to size. I then drill a 3/4” hole to grab the insert for removal that is off-center. Drill and tap four 1/4” x 20 holes for some hex-hole screws that allow for height adjustment (levelling). Then you fit your table saw with a blade that has a smaller diameter than your regular blade (dado or circular saw blade), fit your new insert, turn on the saw and raise the blade. The blade willl make a slice in your insert which can be widened to correct size by simply changing to your regular blade.

You can even make a dado insert using this method. I have used them and have virtually reduced problems with tearout. Watch for a post soon. I need to make anotehr ZCI for my Ridgid.

God Bless,
Hawg

-- Saving barnwood from the scrapyards

View Mario's profile

Mario

902 posts in 4196 days


#3 posted 08-08-2007 05:31 PM

Hawgnutz hit it on the head. You can make them inexpensivly and in large quantity. THat is what I have done. Works good, no extra cost as I always seem to have some around.

-- Hope Never fails

View woodspar's profile

woodspar

710 posts in 4244 days


#4 posted 08-08-2007 06:04 PM

I know what you are talking about because I believe that this is the type that Norm uses on the New Yankee Workshop. If you look at this picture, you will see the insert to the right of the fence, the push stick handle is just over it.

I believe that he is using the “Betterley” insert and making his own wood inserts to fit.

zero clearance insert

-- John

View GaryK's profile

GaryK

10262 posts in 4133 days


#5 posted 08-08-2007 10:10 PM

woodspar – I think that is what he is talking about also. I don’t think that they make those anymore so
that’s why I mentioned using a dovetail router bit to cut the groove if that’s the type of plate he wants.
I kinda like the Betterley design better. That’s why I provided him a link that reviews one.

hawg – Good point about MDF. I had some good baltic birch plywood around so that’s why I used it.
Do you have any trouble with your planer blades getting dull running MDF through it?

Another good source is to get a shelf laminated with melamine at Lowes/Home Depot. It’s cheap, you can get a lot of inserts out of it and the melamine provides a nice slick surface.

-- Gary - Never pass up the opportunity to make a mistake look like you planned it that way - Tyler, TX

View Hawgnutz's profile

Hawgnutz

526 posts in 4221 days


#6 posted 08-09-2007 07:30 AM

Look at my forum post under woodworking skill share for a complete rundown on a ZCI I made this afternoon. They go really fast if you are not taking pictures to document it….LOL

God Bless,
hawg

-- Saving barnwood from the scrapyards

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