Zero Clearance Table Saw Insert

Here's how to install a zero clearance table saw insert on your table saw.  Instructions on how to install a zero clearance table saw insert aren't really that useful, since the item comes with instructions.  I'm writing this really just to share how useful zero clearance table saw inserts can be when making small or thin cuts.

Step 1: Problem

One day while cutting a thin slice of maple on the table saw for a project I heard a loud whack and looked down to notice that my factory table saw insert on my Delta left tilt table saw was badly damaged.

The thin cut-off I was sawing had been sucked down into the blade arbor area and crushed my table saw insert on the way through.  Luckily this all happened very quickly and nobody was hurt, but it really alerted me to the fact that there is a better way to use the table saw to to cut thin slices of of wood - get yourself a zero clearance table saw insert.

Zero clearance inserts minimize tear-out, support even the smallest and thinnest of cuts, and even make your table saw safer.  

Unfortunately they don't clear dust as well since they leave no room for air to be sucked down if you've got a dust collection system for your table saw, but if you use it just for small detail cuts that doesn't really matter much.  The benefits far outweigh the drawbacks on this one.

Comments

[tomtortoise]

The only thing is what if your wood is warped or your fence comes loose during a cut and then the blade starts to wobble? Does the insert shatter?

[moosetooth]

I made an insert similar to this out of a piece of 1/2" UHMW plastic. Worked very nicely.

[Bill WW]

You have a good point, Tom.
Since the insert opening is much more narrow than the standard insert, large chuncks will not be jammed. But smaller cut off pieces can still get caught. It happened to me. I made my insert from a 1/8" phenolic sheet (micarta). When a small piece jammed it gave a "whang", but did not shatter.

[bfk]

NICE job!

Table saws aren't the only tools that can be improved with zero clearance inserts. Looks like it's time for me to replace the insert on my metal dedicated band saw :/

[Bill WW]

I had exactly the same thing happen when making a 45 degree bevel cut. The cut off piece jammed, pushed the blade into the insert. I then made a zero clearance insert specifically for 45 bevel cuts (already had the standard zero clearance insert).

[noahw]

I liked your 45 degree insert so much that I made one myself for my left tilting saw (like yours). Thanks for the inspiration.

I used my 90 degree zero clearance insert as a template however I had to move the finger hole since the original 90 degree location puts your pointer finger right over the blade when it's in the 45 degree location. I also put screws on the side and bottom of the insert so that the insert could be locked into position. I didn't do any height adjustment options however, just planed the piece of walnut down on the planer so it was the exact depth of the insert inset.

Also, you've got do remove more material on the bottom of the insert than you'd expect to have the blade clear when it's raised up...at least that was my experience.

Thanks again Bill WW.

[Bill WW]

Wow, nice job and nice photos!

I don't have a planer, alas. Also, did not have any wanut until two days ago when my neighbor gave me a couple of rough planks.

Now designing and building a rip fence, may turn the project into an Instructable. It will be more of a "how to design and build a modification" Instructable.

Thanks for the comment.

[Jayefuu]

*sigh* I miss having access to a table saw :(

[frammis]

Good clear (and useful) tutorial. I've been meaning to make one for my saw, but haven't gotten around to it. Glad I waited because after reading yours, I find I hadn't considered how to cut the slot. Putting that board across the table to hold the insert in place is something I'd not considered.