Introduction: Table Saw Insert

Make a zero clearance table saw insert that is both accurate and cheap.

Step 1: Stock

Start with a flat piece of hardwood. I chose maple.

Step 2: Width

Cut the stock to the exact width of the insert opening.

Step 3: Compass

Use a compass to find the arc of the insert opening and trace it onto the wood.

Step 4: Sand

Shape the wood with a disc sander. Fine tune the edge with a sanding block to get a snug fit.

Step 5: Jointer

If the stock rises above the surface of the table, remove some wood so that it lies just below the surface of the table.

Step 6: Tap

Drill holes in the four corners of the insert corresponding to the hold shelves on the inside of the insert opening. Tap the holes and insert headless hex screws. Adjust the screws so that the insert lies flush with the table top.

Step 7: Cut

The 10" blade on my table saw did not lower enough to to allow the insert to be completely inserted so I attached a 7 1/4" blade. Make sure the kerf is the same as the 10" blade. With the insert in place, turn on the motor and slowly raise the blade, cutting a slot for the blade.

Step 8: Big 10"

Remove the smaller blade and attach the 10" blade. Repeat the previous step.

Step 9: Finish

Coat with Danish Oil.

Step 10: Finished

At this point the zero clearance insert is complete. The following steps are to include a splitter or rivining knife.

Step 11: Addition

Cut a small line in the bottom of the insert to see the blade line. Drill holes to accomodate your riving knife or splitter. File the hole smooth.

Step 12: Fit

adjust the insert for fit.

Comments

author
rober! (author)2017-04-09

When I made my first insert, I traced the outline of the metal insert that came with the saw. If you leave the line when you cut it to shape, a little judicious sanding will give you that exact fit you want. While you're at it, Make about a half dozen or so to use with your dado blade, too.

author
livichris (author)2016-12-06

I really need to make one of these, been putting it off for ages but it's getting done this weekend.

thanks for posting

About This Instructable

3,419views

43favorites

License:

More by djpolymath:Apartment WorkshopHand Plane RestorationsFrench Polish
Add instructable to: