How can I flatten a phenolic zero clearance insert ?

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Forum topic by HarleySoftailDeuce posted 09-01-2009 06:22 PM 1169 views 0 times favorited 5 replies Add to Favorites Watch
View HarleySoftailDeuce's profile


274 posts in 2506 days

09-01-2009 06:22 PM

Hello gang,
I recently purchased 2 phenolic zero clearance inserts, and for some reason, they are slightly bowed, so they do not fit flat at each end. Can anyone tell me if or how I can flatten it? I did get it as flat and level with the set screws, and clamped a plank on top, and slowly raised my dodo blades until I was through 1/2 inch.
What other material is suited for this task?

-- Paul, Bristol,Rhode Island

5 replies so far

View Sam Yerardi's profile

Sam Yerardi

244 posts in 2982 days

#1 posted 09-01-2009 06:37 PM


-- Sam

View PurpLev's profile


8522 posts in 2735 days

#2 posted 09-01-2009 07:16 PM

you can plane it, but it’s going to be hard on your knives… also, if it’s painted on top – you might end up having a non-uniform colored insert (visual wise).

I used to make my ZCI from MDF, and finished it with poly – it was very sturdy, smooth, and darn cheap!

for my current saw I had some leftover phenolic material that I used for the ZCI though – it’s super smooth and very hard, I really like it. it machines just like wood.

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View robdew's profile


84 posts in 2801 days

#3 posted 09-02-2009 06:11 AM

I just use hardwood scraps. You can machine them just like anything else and they are cheap.

View a1Jim's profile


113816 posts in 2663 days

#4 posted 09-02-2009 06:14 AM

Some heat and weights

-- Custom furniture

View Sung's profile


9 posts in 2780 days

#5 posted 09-03-2009 01:53 PM

card scraper might work, but i agree with jim, heat and weights since we’re talking about phenolic

-- So, how wood jya like that?

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