Today in the shop (replaceable insert ZCI)

[charlese]

Yours appears to be 1/2", but Ed's looks thicker.

I am curious what interferences that might create????

1/2" will give it strength. Just think rabbets.

[reible]

Since there seems to be interest in this I give out a few more pieces of information and then continue as things develop.

The plastic is HMW plastic but I can't tell you anymore then that as I got it as a piece in box of various sizes and colors. It mills like polyethylene and it looked like we had snow here in IL. This is a picture of what got away.

IMG_7427sc.jpg (185.7 KiB) Viewed 3574 times

The thickness is 3/4", the piece of 1/2" felt to flexible even before I started so I opted for the added thickness. If this is a problem I still have several ways to deal with it including milling it down to 1/2". As of now I like how it feels but the area that will be removed for the blades cuts will make a lot of changes so it is wait and see for now.

I do want to point out that this is a first attempt and a prototype so things can be in flux. What seems right in my minds eye might not prove to be what or how things are.

The only critical dimensions I attempted to hold were the dovetail slot and the mdf insert. The wide dimension there was 1-3/8". In order for this to work those dimensions as well as the depth of cut are critical. The mdf was running 1/4" but I used an actual piece to set the depth of cut on the slot and it took off minor amounts to get it flat at the end.

It is also possible that the thickness will have to be changed where the saw blade hub/nuts go. I have not looked at that yet but I don't for see that being an issue in the long term.

For reference this is a picture of the under side with tape in place and the outline of existing shopsmith inserts cut outs. The center line is also shown so if I need to make modifications for the hub it will be center there. I also do not for see needing to cut out the area in the plastic that matches the metal inserts, just enough to cover the normal blades I use.

IMG_7428sc.jpg (79.41 KiB) Viewed 3574 times

The maximum width of dado I can cut is I believe 15/16" with my 8" dado but I will start by making a cut that is only as deep as I normally go and not full depth. Once I have a feel for how things are going I will decide if I will chance going full depth...... I can always remove more material but never add material back on.... Something you learn early on in woodworking.

So I don't think I'll be back on this today as more pressing things are happening, who knows maybe much later in the day??

Ed

The next issue will be finding where the slot needs to go for mounting the top blade guard and associated size of that hardware. I foresee a jig to make the cuts in the brown inserts for those times when it is needs to be replaced. The plastic part will need that cut too.

[rjent]

That is just fabulous! What an ingenious idea!

I will let you work out the "problems" and then attempt one for myself.

The plastic you use, is it like the plastic chopping boards that you can buy at Walmart, or something else? I am very limited in local suppliers here.

[dusty]

That is just fabulous! What an ingenious idea!

I will let you work out the "problems" and then attempt one for myself.

The plastic you use, is it like the plastic chopping boards that you can buy at Walmart, or something else? I am very limited in local suppliers here.

I think that chopping boards (some of them) would work just fine if you can find any that are long enough. The 510 table cutout is 3"x 15 7/8" so you need a chopping board that is at least 16" long.

Eds' design could be done with hardboard as well though the outcome would be much less elegant.

[masonsailor2]

Very nice ! I will definitely make one. I have some corian left which should work nicely. Congrats on a very innovative idea !
Paul

[rjent]

That is just fabulous! What an ingenious idea!

I will let you work out the "problems" and then attempt one for myself.

The plastic you use, is it like the plastic chopping boards that you can buy at Walmart, or something else? I am very limited in local suppliers here.

I think that chopping boards (some of them) would work just fine if you can find any that are long enough. The 510 table cutout is 3"x 15 7/8" so you need a chopping board that is at least 16" long.

Eds' design could be done with hardboard as well though the outcome would be much less elegant.

Thanks Dusty, I can get 24 x 24 boards here. I will start looking

[dusty]

That is just fabulous! What an ingenious idea!

I will let you work out the "problems" and then attempt one for myself.

The plastic you use, is it like the plastic chopping boards that you can buy at Walmart, or something else? I am very limited in local suppliers here.

I think that chopping boards (some of them) would work just fine if you can find any that are long enough. The 510 table cutout is 3"x 15 7/8" so you need a chopping board that is at least 16" long.

Eds' design could be done with hardboard as well though the outcome would be much less elegant.

Thanks Dusty, I can get 24 x 24 boards here. I will start looking

Please let me know where you find cutting boards that large. I need one in the kitchen and three for in the shop.

[reible]

As I figured I'm not going to make any major progress on this today, it is almost 9:00 in the evening and I'm tired.

What I did do was take a look at lowering the table without a blade in place. The insert I built will not allow the table to go the all the way down without hitting things under the table (blade guard stuff). As close as I looked I would say that it will loose about a 1/4" so if I mill the insert down to a 1/2" it will work without hitting anything solid. I'm not sure what effect things like tilting the table might have on this as well so more on that when I get to it.

So if you are looking at material you will want something that is no more the 1/2" thick or be willing to give up some depth of cut. If you are looking to use thinner then 1/2" materials then you might want to look for something stronger then this type of plastic.

I could see someone with the correct type of machine (cnc router) making these out of a phenolic material by the hundreds and selling them for a reasonable price...... got any takers?

Ed

[rjent]

Please let me know where you find cutting boards that large. I need one in the kitchen and three for in the shop.

My wife just informed me (and we know she is ALWAYS right ) that she got hers at SAMS club. I cut one in half and rounded the edges for her as they are too big to fit the counter space that she works at. I have to go down to SAMS next week. I will look and let you know or let me know if you find them there in AZ

[masonsailor2]

I will try the corian idea this weekend. It may be that it will be the perfect material for this. It comes readily in 1/2 inch thickness and very easy to obtain in small pieces. It is also very easy to mill with a saw and router.
Paul