Zero Clearance Inserts

dusty · Post by **dusty** » Wed Jul 23, 2014 11:45 am

We all use table inserts. Some are zero clearance while others are not but we all use inserts.

Buy them or make them? That is often the question but no more. I saw these and knew immediately if I had to pay this kind of money for an insert, I'd make my own. I cannot imagine paying $25 for a table saw insert when they are so simple to make.

JPG · Post by **JPG** » Wed Jul 23, 2014 12:02 pm

dusty wrote:We all use table inserts. Some are zero clearance while others are not but we all use inserts.

Buy them or make them? That is often the question but no more. I saw these and knew immediately if I had to pay this kind of money for an insert, I'd make my own. I cannot imagine paying $25 for a table saw insert when they are so simple to make.

Fear Not! I did not see ShopSmith listed anyway!;)

That product line requires a bunch of different molds I presume.

dusty · Post by **dusty** » Wed Jul 23, 2014 12:11 pm

JPG40504 wrote:Fear Not! I did not see ShopSmith listed anyway!]molds[/B] I presume.

No, I don't think so. HD/PP and HD/PE can be purchased as sheet goods. It is not cheap but it does not seem to be that expensive. I found white 1/2" thick 48" x 96" HD/PP for $250 per sheet (plus shipping).

I have not located it locally and I do not know that it can be cut on a table saw so I may be off in la-la land but that does not change the fact that what I posted is unreasonably expensive. My point of view.

At that price and assuming 90 inserts from a sheet, the cost per insert would be only $3.

robinson46176 · Post by **robinson46176** » Wed Jul 23, 2014 8:14 pm

dusty wrote:No, I don't think so. HD/PP and HD/PE can be purchased as sheet goods. It is not cheap but it does not seem to be that expensive. I found white 1/2" thick 48" x 96" HD/PP for $250 per sheet (plus shipping).

I have not located it locally and I do not know that it can be cut on a table saw so I may be off in la-la land but that does not change the fact that what I posted is unreasonably expensive. My point of view.

At that price and assuming 90 inserts from a sheet, the cost per insert would be only $3.

You can probably beat that price by a bunch for 4' x 8' sheets if you have the right farm & ranch store. Our local Orschlen store carries those big sheets (used a lot in livestock special structures) up to about 1/2" thick. They only cover 9 or 10 states from Indiana and Kentucky west to Kansas and Nebraska.
I have a stash of those plastic laminate flooring samples back to try as inserts. I also have looked at my wife's big high density plastic cutting board from Wally World.

.

JPG · Post by **JPG** » Wed Jul 23, 2014 8:43 pm

robinson46176 wrote:You can probably beat that price by a bunch for 4' x 8' sheets if you have the right farm & ranch store. Our local Orschlen store carries those big sheets (used a lot in livestock special structures) up to about 1/2" thick. They only cover 9 or 10 states from Indiana and Kentucky west to Kansas and Nebraska.
I have a stash of those plastic laminate flooring samples back to try as inserts. I also have looked at my wife's big high density plastic cutting board from Wally World.

.

http://www.usplastic.com/catalog/item.aspx?itemid=23751

lightnin · Post by **lightnin** » Wed Jul 23, 2014 9:19 pm

dusty wrote:I do not know that it can be cut on a table saw.

I am working on a project that includes a small piece of 1/2" HDPE I plan on cutting it with a
bandsaw in the next day or three I'll let you know how that goes.

I'm curious if In can bond it to plexiglas with methylene chloride.

JPG · Post by **JPG** » Wed Jul 23, 2014 10:39 pm

lightnin wrote:I am working on a project that includes a small piece of 1/2" HDPE I plan on cutting it with a
bandsaw in the next day or three I'll let you know how that goes.

I'm curious if In can bond it to plexiglas with methylene chloride.

Paint remover?:eek:

lightnin · Post by **lightnin** » Thu Jul 24, 2014 12:06 am

JPG40504 wrote:Paint remover?:eek:

Methylene chloride is sold at plastic supply stores often called plexi resin.
It basically dissolves the Plexiglas then dries out very quickly making one piece.
it's very thin and is usually applied with a thin needle applicator or glass capillary tubes.
Sometimes one edge is placed into the stuff then held in position till it sets/cures.
It will evaporate through most containers so never buy much more then needed a little goes a long way.
The smallest container they sell is what you want.

Here is a video

Gene Howe · Post by **Gene Howe** » Thu Jul 24, 2014 6:32 am

I use MDF and mill a replaceable insert.
The hold down screws go through the insert.
See it here.

The one shown has been installed a few years and has not needed replacing.
Without the replaceable insert, ZCIs are made for dado blades and angled cuts.

No Walmart cutting boards, or other HDPE was harmed.

videobear · Post by **videobear** » Thu Jul 24, 2014 8:22 am

lightnin wrote:I am working on a project that includes a small piece of 1/2" HDPE I plan on cutting it with a
bandsaw in the next day or three I'll let you know how that goes.

I'm curious if In can bond it to plexiglas with methylene chloride.

Try this: http://tamarrontechnology.biz/adhesives.html: