Plywood Zero Clearance Inserts

[SawEyes]

Interested in anyone's experience making and using zero clearance inserts out of plywood for the tablesaw. I've always used solid wood and/or UHMW. Did it work for you?

-- Regards,

Dean Bielanowski Editor, Online Tool Reviews

50 woodworking product reviews online!

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[Al Reid]

Although I have not used plywood, I have successfully made them from 1/2" melamine. I made them for various dada widths. I suppose plywood would work as well.

[Gregory Jensen]

Hey I have made Many out of small ply 1/8th" but I use / glue 1/2 strips to the underside to give them stability?? Easy to make FAST cheap and basically throwaway. Just make it install it and run your saw blade up through to where you want it!

[Edwin Pawlowski]

Should work. I use 1/2" MDF. Ed

[jo4hn]

[snip]

I use 1/2" ply. I have used solid wood but the piece between the slot for the splitter and the edge tends to break too easily. mahalo, jo4hn

[Bay Area Dave]

which explains your need to use the words you just uttered in the "Charlie..." thread. I have a solid wood insert (poplar) that has plenty of strength by the splitter slot and edge. what TS are you having trouble with solid wood inserts? Mine is a Unisaw. I've never noticed the configuration of other inserts.

dave

jo4hn wrote:

[Bay Area Dave]

I meant "I've never noticed the configuration of the inserts on other models of table saws.

dave

Bay Area Dave wrote: I've never

[mttt]

A'yup! Mine are out of 1/2" Baltic Birch.

[tefgaf]

Following an idea from one of the WW magazines, I made a batch of ZCIs using a sandwich of two layers of 1/4" tempered masonite faced with Formica on top and bottom. These look remarkably similar to the commercial ones made of phenolic and Formica. By inserting 4 screws around the edges, one can easily adjust the height relative to the TS table top. Not sure that appearance counts with ZCIs, but they do look very nice. Partial sheets of masonite are available at HD and counter top installers often sell odd pieces of Formica, so these are cheap to make.

[jo4hn]

PM66

[Lawrence Wasserman]

I've made several from 1/2" baltic birch plywoodthat work just fine.

[bridger]

I make 'em from 1/2" baltic. no problems so far.... bridger

[bobino]

I've used MDF. Works fine.

-Bob

[patriarch]

[e-mail] wrote in news: [e-mail]:

As have I. With 9 coats of hand rubbed, dewaxed super blond shellac, made from flakes distributed through Fort Bragg, CA. ;-)

Didn't we have an exhaustive thread on making ZCI with splitters in the last few months? With detailed instructions?

Patriarch

[Richard Cline]

I used 1/2" Baltic Birch. It was just the right thickness to rest on the insert supports without any corner screws. One problem arose. The regular 10" blade would not retract far enough to fully clear the blade. Hence, I started with a smaller diameter blade and then I could get the

10" blade through the existing slot.

Dick

[skeezics]

i make mine outta 1/2" lexan. [ only cause i found a boatload of it in a dumpster near a plastics shop!] works good and looks cool too! lol.....

skeez

[SawEyes]

Thanks for all the replies. Looks like that pile of scrap ply in the corner of my shop might get used after all :)

-- Regards,

Dean Bielanowski Editor, Online Tool Reviews

50 woodworking product reviews online!

------------------------------------------------------------ Latest 6 Reviews:

- Infinity "Dadonator" Stacked Dado Set

- GMC LS950SPJ Scrolling Jigsaw

- Triton Powered Respirator

- Veritas Power Tool Guide

- Ryobi 6" Grinder/Stand Combo

- Band Saw Handbook

------------------------------------------------------------