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Shop Made Table Saw Zero Clearance Insert

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Forum topic by Hawgnutz posted 2570 days ago 1638 views 0 times favorited 8 replies Add to Favorites Watch
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Hawgnutz

526 posts in 2702 days


2570 days ago

Topic tags/keywords: table saw zci

This is how I make my ZCI for table saws. I like ½” MDF because it is stable (won’t warp or shrink). It usually will fit most contractor or cabinet table saws without any thickness planing. To view images, just click on them and use the “back” button on your browser to returm/ Sorry for the hassle.

First I trace the outline of the original insert on the MDF. (Just be sure not to trace it smaller than the insert! Don’t worry about being too precise. This will be taken care of with a trim router.)
Tracing pattern

Next, measure two finger holes to assist in installing and removing of insert.
measure finger holes

Drill all holes. (I used a forstner bit, but you can use a spade hole bit or a regular drill bit.) Use jig saw or band saw to trim wood. Keep outside of lines, as the final trimming will be done with flush trimming bit in router.
jig saw

Now, we stick carpet tape to the original insert and fasten the new ZCI insert to it, keeping the mounting holes and tabs aligned.
Sticky stuff

Use a flush-trim bit in router to trim insert to match original insert. You can see my outdoor project in background. Red picket fence.
routing

Fine tune new ZCI to fit using file or rasp.
filing

Install new ZCI on table saw and hold down with fence.
fencing down

If your blade does not have enough clearance, like my Ridgid, then stick some carpet tape on original insert and stick new ZCI on top of that. Then install original insert with new ZCI on top. sticky stuff

Then crank blade up until it is fully up. This will cut a slot that is uniquely fitted to that blade. cutting slot

I then write on back of insert the saw and brand of blade it is suited for. This blade is for my Ridgid with Oldham 40-tooth blade.

I hope this helps!

God Bless,
Hawg

-- Saving barnwood from the scrapyards


8 replies so far

View TomFran's profile

TomFran

2942 posts in 2620 days


#1 posted 2569 days ago

Hawg, I don’t know if it’s technical difficulty on my end, but none of your photos are showing up.

-- Tom, Surfside Beach, SC - Romans 8:28

View koopmaun's profile

koopmaun

28 posts in 2824 days


#2 posted 2569 days ago

Hi Hawg. It looks like you left off the file extension of the image. ,jpg or .png or whatever. If you could edit the posting and add that it would be great to see the images.

Cheers,
Doug

-- Koopmaun, Canada, www.screekpaddleco.com

View Lip's profile

Lip

158 posts in 2676 days


#3 posted 2569 days ago

Nice walk through Hawg!

Don’t know what browser or settings the others have … but once I partially allowed scripts for Box.net … the picture showed up.

-- Lip's Dysfuncational Firewood Farm, South Bend, IN

View Hawgnutz's profile

Hawgnutz

526 posts in 2702 days


#4 posted 2569 days ago

I have hard time showing my pics when I post. Don’t know what to do. Maybe switch to photobucket? What do you all use?
They will show if you click on them and use back button to return.

Anyway, I will use this insert today to cut some miters for picture frames. (I sold my compound miter saw and bought a new Incra miter gauge for my TS.) Don;t want the faces splintering. I need to make a jig for measuring my picture frames.

God Bless,
Hawg

-- Saving barnwood from the scrapyards

View WayneC's profile

WayneC

12260 posts in 2723 days


#5 posted 2569 days ago

I use Flickr.

Are you using the insert image button?

Also, where are you getting your URL?

-- We must guard our enthusiasm as we would our life - James Krenov

View Hawgnutz's profile

Hawgnutz

526 posts in 2702 days


#6 posted 2569 days ago

Yep, Wayne, I use the insert picture button. It then gives me three different windows toinsert picture. iS TRHAT CORRECT? I get the URL from my Box.net pisture site. It works if you click on the picture place holder in the post. Go figure. Does Flickr allow you to post pictures easily?

God Bless,
Hawg

-- Saving barnwood from the scrapyards

View WayneC's profile

WayneC

12260 posts in 2723 days


#7 posted 2569 days ago

Flicker is working fine for me. Nice and easy.

-- We must guard our enthusiasm as we would our life - James Krenov

View TomFran's profile

TomFran

2942 posts in 2620 days


#8 posted 2569 days ago

Hawg,

Start using Frickr or Photobucket. Either one is very good.

Actually, I can view your pics if I go to properties and get the URL and add a “jpg” file extension to it, but none of the pictures will display as they should otherwise, and I’m using IE 7.

-- Tom, Surfside Beach, SC - Romans 8:28

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