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Discussion Starter #1
This is old hat for many of the members here, but today I tried something I read here and it worked.
I wanted a zero clearance insert for my miter saw so I took some 1/4" plywood, cut three strips slightly bigger than the stock insert and double-stick-taped them in a stack. Attached the stock insert to the top of the stack with the same tape, and bandsawed close to the insert, all the way around. Then I put a bottom bearing trim bit in my table router and routed the waste away, using the stock insert as a template.
It worked great! That's why this place is so great... I learn something new almost every time I log on!
I drilled the holes using a drill bit that was a close fit to the original holes and then used a Forstner bit to recess the screws.
zcmiter.jpg
 

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2,603 Posts
This is old hat for many of the members here, but today I tried something I read here and it worked.
I wanted a zero clearance insert for my miter saw so I took some 1/4" plywood, cut three strips slightly bigger than the stock insert and double-stick-taped them in a stack. Attached the stock insert to the top of the stack with the same tape, and bandsawed close to the insert, all the way around. Then I put a bottom bearing trim bit in my table router and routed the waste away, using the stock insert as a template.
It worked great! That's why this place is so great... I learn something new almost every time I log on!
I drilled the holes using a drill bit that was a close fit to the original holes and then used a Forstner bit to recess the screws.
View attachment 326369
Hey, Ken, you did a great job. I did the same as you and it works great.
 

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Discussion Starter #8
Thanks, everyone. Now I just need to tune that saw for a bit more accuracy, make zc's for my bandsaw and table saw, and keep working on trying to make my shop cleaner and more organized, etc., etc, etc. I don't think I retired soon enough.
 

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Well done. At one time DeWalt offered zero clearance inserts for their chop saws but discontinued them. No doubt the ease with which one can make their own closed them out.
 
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