Jigsaw/Bandsaw ZCI

Lodgepole · Post by **Lodgepole** » Mon Jan 07, 2013 1:23 pm

I just finished making Zero Clearance Inserts (ZCI) for both my Shopsmith jigsaw and Shopsmith bandsaw. I ended up using 1/4" Masonite for these inserts.

On the jigsaw, I did have to use a couple of dabs of silcone to bring it up to the correct height. On the bandsaw, I ended up having to sand the back down to make the material thin enough to fit the insert hole. But, with the newer style aluminum table, the leveling screws solved any inconsistencies caused by my sanding.

Living in a small, isolated community, masonite was the most accessible option I had for this project. Does anyone have any other suggestions for a different material?

JPG · Post by **JPG** » Mon Jan 07, 2013 1:32 pm

Lodgepole wrote:I just finished making Zero Clearance Inserts (ZCI) for both my Shopsmith jigsaw and Shopsmith bandsaw. I ended up using 1/4" Masonite for these inserts.

On the jigsaw, I did have to use a couple of dabs of silcone to bring it up to the correct height. On the bandsaw, I ended up having to sand the back down to make the material thin enough to fit the insert hole. But, with the newer style aluminum table, the leveling screws solved any inconsistencies caused by my sanding.

Living in a small, isolated community, masonite was the most accessible option I had for this project. Does anyone have any other suggestions for a different material?

I assume you made a ZC insert for every size blade?;)

Lodgepole · Post by **Lodgepole** » Mon Jan 07, 2013 6:41 pm

I just made a few ZCIs up just as a proof of process. Down the road, I may have to make up one for each blade. But, for now, just a fun project.

JPG · Post by **JPG** » Mon Jan 07, 2013 8:23 pm

Lodgepole wrote:I just made a few ZCIs up just as a proof of process. Down the road, I may have to make up one for each blade. But, for now, just a fun project.

Regardless, the sides will be zero clearance.

mrhart · Post by **mrhart** » Wed Jan 09, 2013 10:02 am

Lodgepole wrote:I just finished making Zero Clearance Inserts (ZCI) for both my Shopsmith jigsaw and Shopsmith bandsaw. I ended up using 1/4" Masonite for these inserts.

On the jigsaw, I did have to use a couple of dabs of silcone to bring it up to the correct height. On the bandsaw, I ended up having to sand the back down to make the material thin enough to fit the insert hole. But, with the newer style aluminum table, the leveling screws solved any inconsistencies caused by my sanding.

Living in a small, isolated community, masonite was the most accessible option I had for this project. Does anyone have any other suggestions for a different material?

I was wondering about plexi-glass maybe? Even down here at Lowes, they don't have anything I saw as "hardboard". There was this dark brown board on one side with a white surface on the other side. I bought a piece of that and use it for patterns, but it's not the right thickness for a ZCI.

Lodgepole · Post by **Lodgepole** » Wed Jan 09, 2013 10:08 am

Thanks, I'll have to take a look at plexiglass at the local hardware store.

mrhart · Post by **mrhart** » Wed Jan 09, 2013 10:12 am

That store across from the D9 doesn't have stuff like that does it? They look like they have everything.

Lodgepole · Post by **Lodgepole** » Wed Jan 09, 2013 2:26 pm

I believe they will have plexiglass in stock. If not, I know the ones in McCall will have plexiglass.

Again, thanks for the idea!

robinson46176 · Post by **robinson46176** » Wed Jan 09, 2013 5:03 pm

Go to Wally World and look in the cookware area. Look at the new high density cutting boards. I can't say for sure they have one that thin or not. I have been looking at them as a possible router plate material.

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