Don't mangle your zero clearance inserts

[tdubnik]

After generally mangling my own zero clearance inserts after using then a few times, I decided to come up with a way to set the blade in the same place every time.



I made a hardwood runner that fit snugly in the left miter slot and then attached a crosspiece that extended past the blade. I then set the table against the headstock bumper and locked it down. Next I extended the quill about 1/8 to 1/4 of an inch and locked it down. Then I cut the crosspiece to length by pushing the miter runner with the cross piece attached through the blade. Now I extended the quill with no table insert and set my zero clearance gauge so that the front teeth of the saw blade would rest against the cross piece when I released the quill. I now tightened the quill and raised the table above the blade.



I now inserted a blank table insert and locked it down. I turned on the Shopsmith and lowered the table to make the zero clearance cut. I then raised the table and removed the new insert. I checked the accuracy of my gauge by moving the table and then moving it back against the headstock. I extended the quill and let it come to rest against my zero clearance jig and locked it down. I reinstalled my new zero clearance insert and lowered the table to make sure it would come down with no interferance. As you can see, I shimmed the end of my jig with a couple of tape strips to get the setting just right. Now, when I install my zero clearance insert and use my zero clearance jig, I get a perfect fit. Since I am referencing from the miter slot and not the relation of the table to the headstock, I have not messed up another insert yet.

[dusty]

Fantastic. That is a great idea and equally great execution. I need to make one of those for myself. I don't need to do it real soon because I just finished making a dozen or so ZCIs. I can mangle a few before I run out.

I notice, however, that you made the pictured ZCI such that you can not use your upper saw guard. I hope you will give some thought to extending the kerf back so that the saw guard can be installed.

Your ZCI appears to be made of hardboard (I assume 1/4"). Is that working well for you? I was sort disappointed in mine so I doubled the thickness of the ZCI in the area inside of the table cutout. I have one installed now that was made that way. Jury is still out.

[tdubnik]

Actually the insert is made from MDF and yes I do need to extend the kerf for the blade guard.

The jig is pretty slick because it is fast and references from the miter slot.

[paul heller]

After generally mangling my own zero clearance inserts after using then a few times, I decided to come up with a way to set the blade in the same place every time.

So simple, so obvious, yet I would never have thought of it. Thank you.

Paul

[robinson46176]

OK, maybe I'm just having a senior moment here but I'm just not seeing the original problem...
If I were using a zero clearance insert (keep in mind I seldom use my SS as a table saw) I would just extend the quill maybe 1/4" or less and lock it and lock the headstock to the way tubes. Then I would slide the table over so the slot was over the blade and lower the table down over the slot. After wiggling the blade and table by hand to be sure it was all lined up and not dragging on either side I would then lock the table in place on the way tubes. What would not be lined up well at that point?

[tdubnik]

Francis,

That was pretty much my old method. In my case I would set the table against the headstock and extend the quill until it came through the insert. My problem was that I would get it off just a hair each time until the insert wasn't truly a zero clearance anymore. I would then use a new insert and start the process all over.

I'm just offering an alternative that works for me and MAY help someone else with the same problem.

[Gene Howe]

I like that idea. Anything to make it easier to align is a good thing. Now, if I just had a foolproof method to insure the headstock was locked...........

[beeg]

Now, if I just had a foolproof method to insure the headstock was locked...........

Use the 5 point check before ya turn it on.
EVERYBODY else does.

[tdubnik]

I like that idea. Anything to make it easier to align is a good thing. Now, if I just had a foolproof method to insure the headstock was locked...........

Of course, I've PERSONALLY never done that.

[a1gutterman]

Use the 5 point check before ya turn it on.
EVERYBODY else does.

What's a "five point check"? Just kidding!!!