The following presumes you have a right tilting DeltaUnisaw. Please make the necessary adjustments for your makeof saw, insert thickness and blade tilt direction.How To Make A Zero Clearance Insert With Splitter:1) Go to Home Depot/Lowes and give an eye up to the stackof 1/2" MDF.2) Find a sheet that hasn't been dinged by the fork lifttines during the twice weekly Warehouse Rodeo and JoustingChampionship.3) Wrestle the sheet off and onto one of the (insert colorhere) flat carts.4) Wheel it back to the nice man at the Safety Speed-Cutpanel saw.5) Instruct him to make cross cuts at about 32". You maychoose to use another size(s). Exercise this option now.6) Load the cut sheets back onto the cart, stand in line,let everyone know how peeved you are that you are being madeto stand in line, make an ass of yourself and then pay thenice people at the check out.7) When back at the shop set aside one piece for a tablesaw sled to be built later. Set another aside for futureprojects or jigs and fixtures.8) With the last piece begin ripping the sheet into pieces1/16"ish wider than your table saw blade insert.9) Cross cut the pieces 1/16"ish longer than your insert.10) Make a template. Here's where people usually chime into just use your present insert to make the new inserts. Iprefer to make a template for reasons that will be madeknown shortly.11) Start with your OEM insert and trace a line around itonto one of the MDF blanks.12) Band saw (jig saw) the rounded ends off.13) Go back to Home Depot/Lowes and buy some 3M (Scotch)No. 4011 Exterior Mounting Tape. It has a proper amount oftackiness but isn't so think that the template/item beingcut will shift thus spoiling the cut.14) Double face tape the MDF to the OEM insert with4-pieces of tape 1" long. Press together using handpressure.15) Load router table with router bit having a bearing ontop. Raise bit until the cutter is a red cubic hair or soabove the thickness of the MDF.16) Run the MDF/OEM insert...

Couple of questions. If I buy the MDF at Home Depot, can I use screws fromLowes?Will the Lowes tape stick to Home Depot MDF?If I take someone with me, can I combine steps 13 and 17?What if it is raining: does that make a difference?Your clarification will be appreciated.

How To Make A Zero Clearance Insert With Splitter

Feb 08, 2004 28 Replies

Rate this thread:

Leon 22 years ago

Yeah Ok.. ;~(

Vote

Unisaw A100 22 years ago

You..., you mean, some people actually buy an outfeed table? The next thing you'll be doing is saying that people buy router tables and zero tolerance inserts for their saws. And after that you'll make up some c*ck-mamie story about buying work benches.

UA100

Vote