ZCI Sled

[dusty]

Now that you are all set up, I may need to place an order for some ZCI's That is, as soon as I get a table they will fit. Still waiting on the new Shopsmith. I may even have a space carved out for it by the time it arrives.

When you come over, we'll make a couple. They'll be my "proof of design". If I can make one that fits 'perfectly' on a machine other than the one used to develop it then I can consider it a success.

Actually, I have to make some small changes. The hold downs that installed at the last minute - well, I should have given their location more thought. I tried to drill the screw holes today. The sled worked fine except that the hold downs interfered with the drill chuck. The hold downs must be relocated.

The screw holes are auto located on the center line but I need to develop a way to auto locate on the other axis. I think just a stop against the table edge??? or maybe just a simple drill template???

This was a fun jig. I think that everyone should have something like this unless you do not use ZCIs.

[dusty]

Dusty,

Yeah, I use the upper guard. Once I have cut the insert by lowering onto the SS saw blade I extend the rear opening with a fine blade on my Bosch saber saw. On other inserts I have installed a kerf splitter in the insert to allow for situations when I can't use the saw guard.

Jack

Jack: I no longer use the saber saw for this. I now have a sled that allows me to extend that kerf. The zci is held 'in the sled' for safety and accuracy. Extending the kerf is simply part of the procedure for cutting the kerf.

With an uncut ZCI installed in the sled, I lower the table to allow the blade to break through the ZCI. I then lock the depth of cut lock (table height) and use the sled to extend the kerf in both directions.

The sled is nothing more than a piece of wood with a wooden runner cut to fit the left hand miter track attached to the left under edge.

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I deliberately cut the width of the sled (which rides in the left hand miter track) so that the right hand edge of the sled was at the edge of a table rib. This was done to provide a visual indicator that the sled and table were properly aligned. Since it would be nearly impossible to not be aligned this might be a worthless feature but I did it anyhow.

After cutting kerfs in all the ZCI that plan to make, I move the jig to the table on the drill press. There I drill and countersink the holes in the ZCI. I use a pre-drilled (master) ZCI to position the table for the drilling process. I have no more throw away ZCI because I drilled in the wrong location.

[claimdude]

Jack: I no longer use the saber saw for this. I now have a sled that allows me to extend that kerf. The zci is held 'in the sled' for safety and accuracy. Extending the kerf is simply part of the procedure for cutting the kerf.

With an uncut ZCI installed in the sled, I lower the table to allow the blade to break through the ZCI. I then lock the depth of cut lock (table height) and use the sled to extend the kerf in both directions.

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Nice process there Dusty! Thanks for sharing.

Jack