Table Insert Question

db5 · Post by **db5** » Fri Jan 11, 2013 4:41 pm

I'm considering using HDPE to make four table inserts for my 510. Total cost for materials is $10 plus shipping. I'd like some thoughts on using this material. The cut product is actually 1/16 inches wider. With the 20 inch length I'll have some left for inserts for the band saw. I know I'll have to sand them down to the right thickness.

http://www.tapplastics.com/product/plas ... sheets/529

reible · Post by **reible** » Fri Jan 11, 2013 5:31 pm

I have not used that brand of material but from what I have done I feel 1/4" thick material is too thin and flexes too much. I think using at least 3/8" thick is needed, minimum.

I route the extra thickness away, quick, easy and clean. I have several post here showing the results and if you can't find them I can come back later and look for them.

Ed

dusty · Post by **dusty** » Fri Jan 11, 2013 5:34 pm

I have not done inserts with HDPE but I believe you will be quit satisfied with the results. If you have not made inserts already, I would suggest that you get some 1/2 MDF and try a couple that way first.

I cut my stock to 3 1/16" wide and then round the one end to a 3" arc (half circle. Then I cut it to length. I then go to the router and cut rabbets all the way around; milling out all the material that prevents the insert from setting done in place.

Last step is to drill and countersink the mounting holes.

db5 · Post by **db5** » Fri Jan 11, 2013 7:14 pm

Well, I don't have a router so that's why I selected 1/4. I recently purchased a very good book on routers but decided I wouldn't use one that much so don't plan to get one.

Having said that, my options are SS inserts or making my own. At $4 apiece I think the 1/4 will do unless there is a safety issue and I can't think of one. What am I not considering?

Ed in Tampa · Post by **Ed in Tampa** » Sat Jan 12, 2013 10:43 am

A while back someone posted pictures of HDPE inserts he made. They were excellently done. Do a few searches and you may find the thread.
I suspect it was the other Ed that did it and provided pictural instructions and beautiful pictures of the finished product.

claimdude · Post by **claimdude** » Sat Jan 12, 2013 11:08 am

db5 wrote:I'm considering using HDPE to make four table inserts for my 510. Total cost for materials is $10 plus shipping. I'd like some thoughts on using this material. The cut product is actually 1/16 inches wider. With the 20 inch length I'll have some left for inserts for the band saw. I know I'll have to sand them down to the right thickness.

http://www.tapplastics.com/product/plas ... sheets/529

I bought several phynolic inserts from http://www.ptreeusa.com a while back on-sale for $10 each and am very happy with them. They are a 1/2" thick. They are now $19.99 each but require no machining to install. The 1/2 MDF recommended in this thead also works well (I used some 1/2" birch) also.

Some here may flame PeachTree but I haved used them probably a dozen or so times over the years and have never had a problem. I have placed 3 orders in the past month (sale items) and am please with service and delivery.

Jack

dusty · Post by **dusty** » Sat Jan 12, 2013 11:12 am

This link to a previous thread started by reible might help (I hope).

I make quite a few ZCI so I developed a way to cut the slot and drill the holes in the proper locations a bit more easily. Toward the end of this link are some photo images that show it.