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Table Saw Zero Tolerance Blade Insert

As part of my entry level saw improvements I needed to make a zero tollerance blade insert because the plastic insert that came with the saw was dangerous,the gap around the blade was to big and any small cut off pieces where falling into the gap and jamming between the blade and the insert and on one occasion a piece got jammed and broke the insert. not a good design.

In this Instructable I'm making a 90 degree but I will need a 90 to 45 degree as well

Step 1: Thicknessing the Stock

I used oak for the insert but you can use any lumber that available,here I'm just putting it through the thicknesser to clean the back side off.

Step 2: Cutting the Insert Down to Size

Getting the final dimensions for the insert, I'm using my sled for the cross cut as I get a better finish than the mitre saw

Step 3: Rebating the Insert on My Table Router

Do this in small increments untill it fits in the insert aperature, I had to remove the blade for this as it was to high even when fully retracted .

Step 4: Winding the Blade Up

I had to do this in 2 stages first with a 8 inch blade the with a 10 inch. I clamped the insert down front and back with a couple of planks

Step 5: The Finished Insert

I had to elongate the saw cut to accommodate the riving knife, I used a hand panel saw.

Please check out my video on youtube. don't forget to subscribe,

Step 6:

<p>Hi Marcello,</p><p>I have acquired exactly the same table saw as the one that you have improved. I am planning some similar<br> improvements. May I ask how you clean up the table top surface on this<br> saw? On my saw the thin layer of surface finish on the table top seems<br> to be wearing away so I am afraid that anything abrasive will take the <br>surface off altogether. I'm thinking of making a new table top for the <br>saw but want to try and refurbish the existing one before I resort to <br>that.</p><p>I also want to make a new insert to prevent small pieces of wood from jamming through into the saw.</p><p>Also I loved your video showing your table saw fence. Do you have any dimensions or plans available for this project?<br></p><p>Thanks</p><p>Martin</p>
<p>Hi Martin sorry for the delay replying, i have the same problem with the surface wearing away i just polish the top with marine polish, i don't have any plans i built it on the saw and just improvised it to fit ,but I could give you some dimensions if required, i have a video on making a zero blade insert,</p><p>Oh by the way i have now dismantled the base and i'm incorporating the saw in my work bench to save space as it was getting in the way when not in use hopefully i will have a video out </p>

About This Instructable

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Bio: Retired Boat builder,CNC programmer,Process Engineer
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