LumberJocks

Zero Clearance inserts

  • Advertise with us

« back to Power Tools, Hardware and Accessories forum

Forum topic by Maximillian posted 06-18-2009 12:59 AM 1417 views 0 times favorited 16 replies Add to Favorites Watch
View Maximillian's profile

Maximillian

84 posts in 2741 days


06-18-2009 12:59 AM

Hi
I want to make a ZCI for my table saw for two reasons:
1. Cut down on dust; and
2. provide additional support

Unfortunately, my saw has a cast aluminium insert (approximately 1/8” thick with strengthening ribs), which sits on a ledge in the table top hole. Therefore I can’t make the usual sort of ZCI, unless I rout a lip on the edge of the ZCI. However, that would be too thin for a piece of ply or MDF.
A mate suggested I use a piece of aluminium and raise my blade through that. I am less than keen on that idea, at this stage.
Does anyone have any suggestions?

-- Max, New Zealand


16 replies so far

View lew's profile

lew

11334 posts in 3215 days


#1 posted 06-18-2009 01:14 AM

How about a piece of solid Maple or other dense hardwood?

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Maximillian's profile

Maximillian

84 posts in 2741 days


#2 posted 06-18-2009 01:20 AM

Thanks Lew
Do you think a piece of maple would be Ok with a 1/8” rim? I guess the centre part could be about 1/2”

-- Max, New Zealand

View Maximillian's profile

Maximillian

84 posts in 2741 days


#3 posted 06-18-2009 01:42 AM

Now, that’s a great idea, because Lexan is probably more easily available in New Zealand, than Maple.
Thanks

-- Max, New Zealand

View lew's profile

lew

11334 posts in 3215 days


#4 posted 06-18-2009 01:55 AM

If you use a polycarbonate, take care when raising the blade. You will want to avoid excessive heat build up at the cut to prevent melting and warping.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Greg Wurst's profile

Greg Wurst

786 posts in 3292 days


#5 posted 06-18-2009 02:38 AM

Make it out of 1/2” baltic birch. Use the original insert to trace the outline and cut it (and several others) to size. Then, rout the needed recesses on the edge on the router table. Odds are you can set it to a certain depth and rout around the entire insert. That’s what I did on my old Craftsman table saw with a similar metal insert.

-- You're a unique and special person, just like everyone else.

View PineMan's profile

PineMan

71 posts in 3054 days


#6 posted 06-18-2009 03:51 AM

Any good strong hardwood would work.

What exact saw do you have?

-- I never started a project I couldn't screw up.

View Maximillian's profile

Maximillian

84 posts in 2741 days


#7 posted 06-18-2009 05:09 AM

The saw is made by SMI in China and is sold under a variety of brand names. Mine is a 10” cabinet saw from Jacks machinery in New Zealand. I don’t know whether you would have the same model in the U.S.

-- Max, New Zealand

View herg1's profile

herg1

42 posts in 3173 days


#8 posted 06-18-2009 01:53 PM

Max you shouldn’t have any trouble doing as your friend suggested by using an aluminum plate and cutting through it. Just clamp the plate down by placing your fence over the edge of it (keep clear of the blade path) or clamp a board over the plate to hold it in place as you “slowly” raise your blade through the plate.

Make sure you use a carbide tipped blade, an inexpensive one will work. I would make several of them for future use once you are set up.

-- Roger1

View Maximillian's profile

Maximillian

84 posts in 2741 days


#9 posted 06-18-2009 10:29 PM

Thanks Roger
I take it that this will ruin the blade for fine woodworking and that I should throw it away after cutting the aluminium.

-- Max, New Zealand

View RedShirt013's profile

RedShirt013

219 posts in 3122 days


#10 posted 06-19-2009 05:56 PM

Try using a small sheet of UHMW. They are smooth and as easy to cut plus more stable than wood. Also very easy to make the rabbet with a router bit

-- Ed

View Chris Wright's profile

Chris Wright

540 posts in 2941 days


#11 posted 06-19-2009 06:04 PM

You shouldn’t ruin the blade cutting through aluminum. Sure, it may not be as sharp as it was. I’ve used a regular carbide tipped saw blade to cut sheet aluminum up to eighth of an inch with no problems. You could use an older blade that you’re about to have sharpened or replaced anyway and then you don’t have to worry about that blade anymore.

-- "At its best, life is completely unpredictable." - Christopher Walken

View TopamaxSurvivor's profile

TopamaxSurvivor

17654 posts in 3136 days


#12 posted 06-19-2009 11:15 PM

If you do use wood, you can strengthen it by putting a layer of epoxy in there to level the plate with the saw top and to strengthen the insert. That is the way rifle stocks are bedded and strenghtened in weak areas. As long as the epoxy is abut 1/16th where it bears and a little thicker adjacent to that in the hole, it shoud be fine. Use plenty of Johnson’s wax as a release agent on the saw. It’s much more reliable than any of the spray on stuff I’ve ever used.

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View SCOTSMAN's profile

SCOTSMAN

5839 posts in 3045 days


#13 posted 06-19-2009 11:31 PM

Raising the blade as long as it’s tungsten is the way to go through aluminium I have cut aluminium many times with my saw it cuts like hard wood watch the chips with your eyes though Alistair

-- excuse my typing as I have a form of parkinsons disease

View TopamaxSurvivor's profile

TopamaxSurvivor

17654 posts in 3136 days


#14 posted 06-19-2009 11:40 PM

Aluminium will gall and cling to you teeth too. Can gum up a blade in nothing flat:-((

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View tyson's profile

tyson

43 posts in 2844 days


#15 posted 06-20-2009 01:23 AM

when i had that type of a saw i used some left over laminate floor i had, i think it was 8 mill, it worked realy well

-- a truly wise man never plays leap frog with a unicorn

showing 1 through 15 of 16 replies

Have your say...

You must be signed in to reply.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics

HomeRefurbers.com