Yes this has been done before and I'm sure I even remember a post here on the forum about the concept but I could find it or remember who posted it... sorry.
As some of you are aware ZCI zero clearance inserts can be made in varrious ways. I have posted several of them over the years and there are a lot more out there. Todays efforts are making an insert that fits in an insert..... yea got ya thinking now right?
The idea is that you take the time to make an insert that fits your shopsmith table and then have an easy to replace insert that fits in that insert so that in the future you only have to make the really simple insert. Clear as mud?
Keep reading I think the pictures will help. The white piece is the "holder" and the brown is the insert. The white piece can even be left in place and by removing the back screw the brown insert can be removed.
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I left a small "tail" extending out the back to make this sort of swap easier.
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And yes I did my homework and the rip fence doesn't hit it.
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I started by cutting the plastic to width and just a little long. I then went to the router to make the area where the insert sits. I used a spiral bit to remove most of the material.
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I then came back with a 1/2" 14 degree dovetail bit for the start of the sliding dovetail. One side is easy, the other you have to come in backwards to avoid back routing but it works.
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The results give you this:
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With this part done you now need to make it fit the table. I used a dish bit to do that and this is what that results in.
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- IMG_7421sc.jpg (129.29 KiB) Viewed 4760 times
The matching insert is cut with the same dovetail bit and looks like this.
- IMG_7422sc.jpg (173.42 KiB) Viewed 4760 times
The insert then slides in.
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I'm up to the testing phase where I will see how well my idea works and if I have to make any modifications. I also have to be able to reproduce the inserts without to much difficulty, something I think is quite doable. I'll keep people informed if there is interest.
Ed
