how do I make a zero clearance insert?

[vbgregg]

Hi,

Can someone please give me instructions on how to make a zero clearance insert (ZCI) for my table saw? Is MDF the best material to use? My current (non-ZCI) insert is 3/8" thick. Do you use 1/2" MDF and route the sections over the TS tabs so that the insert sits low enough, or do some places sell 3/8" MDF? Do you trace the shape of the stock insert onto a piece of MDF and then cut close to the line with a band saw and then sand a little at a time until it fits? What do you use for the height adjustment screws and the hold-down pin in the front?

I think Bruce talked about this at a TWA meeting last year, but I did not take notes. Any help from Bruce or others would be appreciated. I'm sure this is easy, but the more details the better! Thanks,

Gregg

 

[rhett]

In the past, I have used 1/2 mdf. Rough out the shape and then apply dbl stick tape to two sides of scrap 1/4". Stick the mdf to your present metal insert. This makes a space between the roughed out shape and the metal insert so you can safetly flush trim the mdf to exact size without worry of the bit hitting the metal insert. Now take the mdf insert and run it vertically against the fence to get the two sides down to the proper thickness. If you want to get slick, cut it down the thickness plus a little more than depth of a 1/4" screw head. This will allow for tuning it in to the proper table height. Some might chime in and say this is not safe, but I then move my fence over the blank within 1/16 of the blade. Turn on the saw and slowly cut up into the insert. Done.

 

[DaveO]

http://www.woodweb.com/knowledge_base/Zero_Clearance_Table_Saw_Inserts.html

http://www.shopnotes.com/issues/090/videos/making-a-zero-clearance-insert/

http://www.woodsmith.com/issues/146/videos/making-a-zero-clearance-dado-insert/

http://www.woodbutcher.net/insrtsaw.htm

http://www.woodworkforums.com/archive/index.php/t-10941.html

Just a little light reading with your morning coffee :-D

Dave