Shopsmith Forums

I make my own Zero Clearance Inserts for my 500 out of 1/4" hardboard that has been laminated with standard formica. The combination is the exact thickness for the 500 table and it is perfectly even with the top surface of the table. I do the lamination myself which is very easy. The surface is quite smooth and easy to move wood across with no waxing needed.

I make my own zero clearance inserts using 1/4" hardboard scraps. I adjust for the very slight step by putting a split washer under each screw and just tighten to fit. And I have a separate ZCI for each of my saw blades (plywood, carbide, planer, etc.).

Works like a charm for me and it does reduce chip-out on the bottom of a piece, prevent small slivers from falling down between the blade and insert, and does help the dust collection.

I make them in batches of a dozen or so and don't feel guilty when I have to throw one away because the slot has opened a little. And I just center the blade in the slot manually for each set-up.

I made three new ZCI this past weekend using some cherry cutoffs. Except for my craftsmanship errors (which we need not discuss), they came out looking good. Only time will tell if cherry is a good material for this application.

I have been using two pieces of 1/4" hardboard glued together to get the 1/2" thickness I want. This time a milled the cherry to size and shape.

For my project, making repetitive 30 degree bevel cross cuts, I remove the ShopSmith insert and built a sled. Sled base too serve as a Miter and ZCI. If works as plan, I shall add hold down clamps for work piece.

dusty wrote:How popular are Zero Clearance Inserts?

We all use Table Inserts but how many of us use ZCI?

Of those who use ZCI, how many of us make our own?

http://www.shopsmith.com/ownersite/cata ... nserts.htm

Thinking also of your other thread regarding making inserts, where you want a workpiece 1/4" or thicker, thot I should mention that example e at ss-link sits way under the tabletop level. I prefer mine to be at level. Of course for long pieces it don't really matter.

terrydowning wrote:Home made ZCI is my go to when sawing. I use hardboard cutoffs, and laminate flooring (which just happens to be the perfect thickness).

perfect thickness-- and that is... ?

I've got at least 5 different SS inserts (yes I am a "Sale" junkie) and at least 5 different thicknesses when mounted. Wonder if there is considered a (more or less) perfect average to shoot for?

dusty wrote:This is a question for those who make their own table saw inserts.

Do you strive to level the insert with the table top or is a slight step (.008" to .010") between the table and the insert considered tolerable.

AHA! There's the question I shoulda axed. With big stuff that spans the throat there's no problemo. But cutting small stuff is a royal pita when you've got one end of it dropping into the "pit", snagging on the rims, etc.

Makes me wonder what possible benefit there can be with a thin insert.

[quote="easterngray"]I make my own ZCI's from 1/4" tempered hardboard]

If a number of hardboard users (of the 5 different types) were surveyed, would we learn if a pure 1/4" is the true thickness? Or do "we" know already?

keakap wrote:perfect thickness-- and that is... ?

I've got at least 5 different SS inserts (yes I am a "Sale" junkie) and at least 5 different thicknesses when mounted. Wonder if there is considered a (more or less) perfect average to shoot for?

As noted earlier I am not a person to do a lot of measuring. Measuring can become a habit and very distractive from woodworking. Also very frustrating.

The perfect thickness for an insert is -- the thickness that when installed will be perfectly flush with the table top.

For inserts that do not reach the top perfectly, you can always add masking tape to the bottom of the insert until it is flush.

For inserts that are too thick - the trash can!!!

charlese wrote:As noted earlier I am not a person to do a lot of measuring. Measuring can become a habit and very distractive from woodworking. Also very frustrating.

The perfect thickness for an insert is -- the thickness that when installed will be perfectly flush with the table top.

For inserts that do not reach the top perfectly, you can always add masking tape to the bottom of the insert until it is flush.

For inserts that are too thick - the trash can!!!

Onct again, I have been over-noodling this question. I hereby resolve 1) buy no more inserts from SS (or anybody else); 2) find that perfect thickness for THIS table and run twenty or thirty feet of stock through my planar for future ZCIs.

Thanks!