Zero Clearance insert for 1950's Craftsman TS

[Mark Gottesman]

I need to make some ZCI for my Craftsman "100" TS. It has the original throat plate which is a piece of 3/32" thick aluminum. so it is thin and is prone to bending. Not an ideal material.

There are new after-market ones available for about $25.00 apiece, but that seems expensive if I want a variety of them available.

So, yesterday, I made one from 1/2" plywood. First I used a flush trimming bit for the profile and then went back with a guided rabbeting bit to carve out the step/ledge that the insert would ride on. Then I have to go back and trim each end since the table ledge is about 1/2 " on the rounded edge and 1/4" on the sides. Finally, I spent some time with a file to get a proper drop-in fit and shim the bottom with tape to get it to fit flush.

Basically, the process was a bit long and convoluted for my taste. Also, I chipped the thin edge when prying the ZCI off the carpet tape.

I did like how the new ZCI fit tight, flush and did not flex.

So, after all the lead in, my question is does anyone have any thoughts on how to make this ZCI without this amount of fiddling about?

A great "Happy New Year" to everyone.
It's been a great day today. Had a Bluebird and a Robin out back and my winter garden looks green.

Mark.

 

[SSuther]

I've got the same situation with a 30's era Craftsman table saw. What you did was what I've thought about, but it just occurred to me that you may get good results by making it out of two pieces of thin material, then laminating them to get the needed step. I haven't found my round tuit yet to get this done.

 

[jeff...]

Make them! you can, of oak or maple or ...

 

[Gotcha6]

I made one from some 1/4" birch the same way and glued a rabbeted block to the back to hold it in place. Mine original only had a spring clip but it's not as old as yours. Had to rabbet the edge like you did, but it holds up OK.
When I went to make one for my new(er) table saw I cut out several blanks to save the setup trouble.