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I had some time in the shop and decided to re-make my zero clearance inserts. I made them for my Dewalt Contractors saw. I have made them in the past from plywood, and mdf. I don't like plywood (too much drag). This time I tried some left over 3/8" laminate flooring on one and also 1/2" mdf on the other. I thought that using the bottom side of the laminate as a top surface was a good idea because it has a finish of hard plastic and very smooth. The laminate being 3/8" had to be shimmed to end up the right thickness(1/2") to fit into the opening and rest on the machined casting. I did this by dadoing the bottom side, then gluing maple pegs to raise it even with the top. I decided to make another from 1/2" mdf as a spare. It got me thinking about the maple pegs I glued with titebondII. I suppose the pegs are there to keep the insert from being ejected back at the user in case the blade somehow caught it on the far side of the insert. The operator's end is held down by a cam. It got me wondering about other brands of saws...How is yours fastened? I included detailed photos showing my inserts. I use one for thin kerf, and when it gets worn, I then use it for a full width (1/8") blade so I get more life from the insert. I also mark a line so I know at what point to measure the height from.
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