Oh yeah, while we're on the topic: If you now (for whatever reason...) happen to have an extra phenolic zero-clearance insert, you can use my method to reset the openings, then use one insert for your thin-kerf blades and the other for your full-kerf blades. You're welcome. :-)
Seriously? Out of phenolic? Rough-cut to general size on the bandsaw, milled to actual size with a flush-cut bit on the router table, drilled and tapped for leveling screws, drilled for a finger removal hole, a small hole drilled in just the right spot on the back edge to insert a roll pin to prevent the blade from lifting the insert out of the slot, and perhaps extra drilling or cutting for a splitter or riving knife? Mine also requires extra milling on the underside so the insert clears the blade stabilizer and/or arbor nut. All that so you can avoid the smell of epoxy? Whatever...
Jeez Steve, of course all that is easier than squirting out some epoxy, mixing it up, pushing it down into the slot, going out on the back deck with a good beer and waiting all those minutes for the epoxy to cure. sheesh. What were you thinking?
Yeah, I was thinking the same thing. I have about five different kinds of epoxy around here, and only one (Bondo marine epoxy, which you can't buy any more) has any significant odor (the hardener smells strongly of ammonia), but even that's not noticeable unless you stick your nose right in it.
Thanks. "Fast" of course depends on what kind of epoxy you use. In my experience, the strongest epoxies tend not to be those that cure quickly, particularly those of the "5 minute" variety, so I would normally expect this to be an overnight operation. I recently bought some of this stuff:
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it cures about as quickly as I could expect without sacrificing any strength or adhesive qualities. It also has relatively low viscosity, which I prefer for good penetrative characteristics on materials like wood. It's pretty good stuff, and it would work very well for the phenolic insert application.
A waste of good epoxy? To renew a zero-clearance insert? It takes all of about 1/2 ounce of epoxy to get the job done. Sometimes I have more than that left over from most of the woodworking tasks I use epoxy for.
snipped-for-privacy@gmail.com wrote in news:aff878c1-80b9-4597-8975-945c6afbb166 @googlegroups.com:
I've used tape to reduce the chipping and it does help. A sharp blade helps quite a bit too.
The only problem with making two cuts is the final edge isn't likely to be smooth. If you're edge banding, it might be a problem. You may want to make the second cut full-depth to try to eliminate this.
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