New replaceable ZCI prototype

Gene Howe · Post by **Gene Howe** » Tue Jan 26, 2010 5:19 pm

I've long wanted a ZCI that could be replaced without having to make a new one. A little slack time in the shop and came up with this prototype.

Started with a piece of 1/2" MDF. Just like making a new insert, using a trim router and a template, made one to fit. Then trimmed it on the router table to the correct thickness around the edges. Turned it over and cut a 1" wide recess,
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Cut a piece of walnut for the replaceable insert, rounded the ends and drilled the holes.
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Fits pretty good.
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The next one will be BB and 1/4" ply for the insert. And, make templates for use of the OPR.
What do you think?

Gene

wa2crk · Post by **wa2crk** » Tue Jan 26, 2010 5:29 pm

Gene;
I like it!!
I'll have to try to cobble one up for a 520 table system.
Bill V

a1gutterman · Post by **a1gutterman** » Tue Jan 26, 2010 7:14 pm

Sharp looking insert, Gene!

charlese · Post by **charlese** » Tue Jan 26, 2010 11:00 pm

Great idea Gene! Thanks for showing it!:)

joedw00 · Post by **joedw00** » Wed Jan 27, 2010 9:11 am

I like the idea Gene thanks for sharing.

kd6vpe · Post by **kd6vpe** » Wed Jan 27, 2010 9:55 am

Very nice work there Gene. I saw Norm had one simular on his saw it was metal you have come up with a great idea. Can't wait to see what the rest of you come up with next for the 510/520's. thank you

Ed in Tampa · Post by **Ed in Tampa** » Wed Jan 27, 2010 10:16 am

Great Idea. One consideration though. The two hold down screws on the SS also serve as a leveling screws for the insert. SS inserts the insert is coined (slightly bent) therefore as the two screws are tightened the insert is pulled down. The instruction manual explains adjusting the height of the insert to table adjustment is made by tighten the screws as you check the eveness of the insert to the table.

No big problem to overcome but you have to be mindful that as you make the insert the thickness of it on edges will effect how it sets in your table. Too thick and the insert will set high too thin and it will set low.

pennview · Post by **pennview** » Wed Jan 27, 2010 10:31 am

Outstanding idea, Gene! Thanks.

Gene Howe · Post by **Gene Howe** » Wed Jan 27, 2010 10:32 am

Ed in Tampa wrote:Great Idea. One consideration though. The two hold down screws on the SS also serve as a leveling screws for the insert. SS inserts the insert is coined (slightly bent) therefore as the two screws are tightened the insert is pulled down. The instruction manual explains adjusting the height of the insert to table adjustment is made by tighten the screws as you check the eveness of the insert to the table.

No big problem to overcome but you have to be mindful that as you make the insert the thickness of it on edges will effect how it sets in your table. Too thick and the insert will set high too thin and it will set low.

It took some T&E to get it perfect but, I now have some "set up blocks" for repeatability.
I haven't used a stock insert for probably 15 years. My old method was to mill a bunch from 1/4" ply, apply hot melt glue in spots around the perimeter and, put it in place. When it cooled, I had custom levelers. I always marked which direction to set it in.
You don't realize that 1/4" plywood varies so much, even from the same sheet, until you work with such tolerances.

dusty · Post by **dusty** » Thu Jul 24, 2014 7:39 am

kd6vpe wrote:Very nice work there Gene. I saw Norm had one simular on his saw it was metal you have come up with a great idea. Can't wait to see what the rest of you come up with next for the 510/520's. thank you

Good show there Gene. I like that.

Gene has already done the design work for a generic insert. Just make some minor changes to facilitate the squared off outfeed end of the 510 table insert and you have it.

Gene's design (with mods) will work on the 510.

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