DIY Zero Clearance Table Saw Insert / Choosing the Right Blades 

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I appreciate your attention to detail in every project. It’s inspiring. Thanks!

I just ran across your channel looking for insert ideas for my Delta. That’s as clean as I’ve seen yet. I’ve never seen the MDF material you used that’s colored and coated like that here in the states. Your attention to detail is spot on and I appreciate your craftsmanship! Very well done! Thank you for posting this. Subscribed*

Thaks a lot! Especiallly the tip with the washer in the back to secure the Jig is great!!!

There's a channel, hooked on wood, where the author showcases inserts with holes and slots adjacent to the blade slot for the purpose of allowing dust to be sucked into the machine. Gonna add those too once I start doing mine

Pekerjaan anda sangat sempurna. Saya sangat senang melihat video anda. Sy hanya bisa bermimpi bisa bekerja seperti anda. Padahal kayu di daerah sy masih berlimpah. Sy di pedalaman Kalimantan. Indonesia

One of the best inserts I’ve seen built your attention to detail is always on point thanks for sharing

Excellent video. I made that modification to the riving knife on my Dewalt to allow the throat plate sides to be connected at the rear. That knife is made from some tough steel. I wrecked two metal cutting jig saw blades trying to cut that notch and made no progress at all. Instead of knife, they should call it a riving katana. Anyway, I finally just ground it down with a bench grinder, filed it smooth, and painted the bare edges with a paint pen. Took about 10 minutes max. That mod is a great idea, but it would never have occurred to me, so thanks!

Es justo lo que necesitaba. Tengo que renovar el inserto de mí dw745. Y estos son geniales

Thank you for the detail demonstration. I've just an insert following your experience)

Excellent tutorial and sequencing to build quality Z-clearance inserts. Like your washer lock system! Thanks very much for all your great video work, with excellent designs and fabrications!!

Magnífico maestro es usted genial de Aguascalientes México Francisco gamez un abrazo muy fuerte y saludos cordiales bendiciones para usted y toda su familia 😯👍👍👍👍👍👍👍👍👍💯

Well. If what you’re saying is true. You can’t cut without a riving knife. With a dado blade, you are not cutting. You are scoring. Cutting implies separation which is not the case when making dados. Since you’re not cutting, the risk of pinching the blade is significantly lower (virtually zero).

You are amazing! You are a true perfectionist.

The Riving knife isn't the problem. The problem is with the 10 sec slowdown rule, the weight of dado blades and the way how blades are locked on table saws: In Europe every non-covered woodworking machine (or maybe even metal working machines) must stand down within 10 seconds after you push the stop button. (But in practical it's much shorter). To accomplish this rule the motors have some kind of built in braking solution. If you think about the direction of the nut it is designed to be self-locking and provide constant locking force on the blade while the saw is spinning. Theoretically you're in safe even if you doesn't pull the nut properly, until the blade is standing perpendicular to the shaft. (Obviously, don't try it). However when you stop the saw and the brake is activates a counter-rotating force occurs on shaft. Eventually this - and the momentum of the blade - starts to loosening the nut. For normal blades table saws are designed. Manufacturers calculate how much force have to apply for braking to not loose a properly applied nut. But dado blades have much-much more weight and therefore much higher momentum during shutdown. So dado blades are NOT prohibited in Europe. They're just incompatible with the extra safety functions which have to be built in into a table saw in Europe.

Class, pure class

Thanks my friend!

Работа просто супер 🔥💪👌👍

Where I live, there aren't any of those types of wood available within 200 miles. Even then its an "Iffy" proposition. Melamine coated colored MDF is unheard of even in search engines here. MDO is a plywood used for road signs in highway departments. Specially made. Usually not available except by special order with LONG waits. I absolutely LOVE your designs and their look. Practically none of the material you use is available and it would be cost prohibitive to say the least. Hooked On Wood makes similarly ingenious designs --- in the Netherlands.

Very precise thanks for sharing

Real nice video on table saw inserts. Thanks.

terimakasih sharingnya pak

I had learned👍

Πολύ ωραίο,συγχαρητήρια !

Nicely done.

Great work again!

Super Arbeit 👍👌🙋‍♂️

I'm curious why you're concerned with making the riving knife work with the dado stack. I thought the purpose of the riving knife was to prevent the separated pieces of wood from pinching on the blade after they pass through. I wouldn't think this would be an issue with a dado since you aren't cutting through the wood, but just making a groove, so there is nothing that can pinch together on the back end.

Excellent wow !

You can also cut the blade groove through the thick MDF using a saw blade of a smaller diameter mounted on the saw. Just make sure it is the same or smaller width.

Hello hello, love the video as always! And routine time: Fence～Fence～Fence～ Hahaha

What is the white and dark gray mdf type board are you using for the table inserts and Where in the united states can I buy this product? Charles

You could get away without "shaving" the riving knife if you leave a lip that goes below table surface. Look at the original insert plate, there are two small tabs. I believe there is enough room to have the lip entire width from tab to tab position and make it even longer. This way you can have your groove for riving knife go a bit further without breaking the insert plate. You have to engineer a locking mechanism similar to original in front though but there are plenty of alternative designs in youtube for that.

Amazing

Why would you still use the original insert if he's working less good and precise? Do you have any downside of your own insert? Thanks for your work! Since yesterday, my sled is functional, one week after receiving my table saw.

Excelente tutorial cómo siempre , un trabajo impecable , gracias por compartir tanta información y conocimientos , un saludo cordial y por supuesto un gran like desde Narón (Galicia) 🤓 🛠️ 🔝

Hi! I have a question about saw blades. Their thickness is 1.6 mm, the width of the cut is 2.3 mm. The thickness of the wedging knife is 2.2 mm. Do you ever have a knife stuck in the cut?

Hi Thanks for the video :) What size is the hole Ind the dado blade? Normal blades are 30mm for this saw. The reason I’m asking, is that I’m thinking of buying the CMT dado blade stack. It has a 30mm hole. Would that be a problem? Thanks

Great video as usual from your chanel. Thanks for sharing, by the way, what if a "Driving knife" can be modified with different thickness to match dado blade? using same metal to insert and hold it in place, but modify the thickness in order to keep a level of protection?

Hey there,like very much all your projects. Detailed and well thought. I have question about cmt dado blade set. I daw that when you used full stack that you didn't insert washer is that right? Or there is enough space in order to fit complete dado stack. Best regards and keep greatness going

I’m looking to do something similar on my Delta 36-441. Has stock splitter that is huge and in the way w attached blade Gaurd - I’m tempted to just re use the splitter but cut it down so I can use micro jig but then I won’t have the splitter/blade Gaurd again in case it doesn’t work out well- any suggestions from anyone?

which table saw you are using what is the modle number please

Fantastic stuff as usual, thanks very much Paolo. Have you not felt the need to shorten the height of the riving knife?

We have a lot of the same tools. I have that same table saw, the 12v cordless Bosch router, and I have the 24t and 60t CMT saw blades. Question: does your 60tooth have a high pitch sound when it spins freely? Mine is awful. It's a great blade that cuts really nice, but the high pitch sound is really annoying. I try to use hearing protection most of the time, but sometimes I just need to make one fast cut and don't have any hearing protection on me at that moment, and in those cases, I hate using that 60t blade. But it's only there while the blade isn't cutting.

Hi, I bought the same DeWalt saw, I'm in Europe. Two questions: are CMT blades with think kerf really compatible with the standard riving knife. Don't you get a slight misalignment since the kerf is thinner than on standard blades? Would a 254mm (10") blade also work or is it too wide? Thanks for you reply and I love your amazing work by the way!

Top....

Hello there, 1st time I've seen you using double blades on a dwalt table saw, is it possible

Dear, I wonder if you change the original bolt to tighten the blade ? Also, did you ever encounter any loosend blade using the dado stack? Thanks a lot for your answer

The manufacturer is not recommend using the Dewalt table saw with dado blade, but i want to use it after having a Workbench for my table. Can you share your experience while using dado blade with dewalt saw?

beautiful and useful video, congratulations. but I can't figure out what material you use for the final piece. I cannot recognize the gray material you use for many processes. maybe i missed his name. could you tell me? thank you very much.😃

Hi Suso have you a link of dado blades?

@Paoson Woodworking hello . I order the saw today. What is name this plastic material or you can send some web page? Thnaks

There is no requirement in EU for a riving knife when making non trough cuts. It's fully acceptable to remove it as it will serve no purpose if it's with is not matched to the blade. The only limitation to dado blades I can find besides what you menthion about being able to mount it securly is a recomendation to use a shaper instead for production runs.

I was hoping you touch on the parallelism adjustment when you set the blade at 45°. The trunnion is a bitch to adjust on the DeWalt. There is literally no room. My blade was adjusted perfectly at 90° May be .05mm off. But at 45°, parallelism was off by .18mm.

Dear, thx again for your videos ans plans. I'm nearly done with the build of my mobile workbench based on your plans. I've bought the same blades as yours but saw that the riving knife of my saw (same of your dewalt) is mentioning that it allows blades above 1,5mm kirf. The ones we have are 1,4mm. I wonder if it was a problem for you ? Aren't the pieces of wood thightend vu the knife against the fence ? Thanks a lot for your answer

What DeWalt saw are you using? Does it comes standard with a 250mm blade?

❤️

they're only truly zero clearance when you raise the blade all the way up, so you'd actually need different inserts for different heights of the blade.

Excellent video on zero clearance inserts. What model of Dewalt table saw do you have?

Nice inserts but I don’t understand why you run that blade higher than needed or recommended.

What machine you used????

How do you keep your tablesaw so clean under the saw blade?

You have a CNC router, why not make the whole insert on it?

Very compliments 👏🏻👏🏻 what is the model of the saw?

Что за материал использует, кто подскажет?!)

What table saw is that please?

I would be interested to buy your Z-clearance inserts…you could realize and sell a set to me?

What is the name of this high density MDF w/ melamine?

Also trying to find a similar material. What would it be called? HDF + Melamine?

Riving knife is only needed when cutting completely through the board. ...if you aren't cutting all the way through then there is nothing to "rive" (split apart), so no safety issue and no legal need for a riving knife. Biggest problem with dado blades is that you need a fairly decent motor brake to stop the additional mass within the required 10-sec spindown time. Many job-site saws won't manage it but any decent full-size cabinet saw should be fine. They'll be designed to work with heavier and larger diameter blades so a small diameter dado stack shouldn't be an issue.

*Great Video!! Definitely going to Build this for My Saw* 🌟👍🏻 *I also Bought the same Table Saw but I didn't get a default Blade in it and I need buy all 3 but don't know which brand blade to buy coz in India I'm only getting 80t DeWalt Blade but not getting 60t and 24t so can anyone suggest which brand blade should I buy in India??* *And I have a 10" Miter Saw Blade and when I put it in my saw there is a difference in blade and riving knife how do I adjust it?? If I could attach photo it would be better to understand*

Hi, absolutely addicted to your videos; that is my dream workbench. I can't find the link to the plans for this bench - can you please provide (in Messenger if you prefer)?

Prize kiya he

you will need the original if you plan on cutting wood on angles

I wish I could find this 13mm material in Texas. I have had ZERO luck locating anything like it.

Not sure if I missed it. but what is the new zero clearance Insert material made out of? Otherwise great video thank you

What material do you use for the Zero Clearance Table Saw Insert?

Would you be interested in selling me two inserts? I live in Denmark

*First* 👍🏻

Not. In Europe is different problem. Who cares about riving knife? Who cares about regulations? On all Europena saws is possible to easy remove riving knife. In case of regulations/laws this will be technicaly obstructed. Allways using riving knife is only in safety instructions. There it's nothing about laws and regulations. European saws simply haved short shaft for dados use... :D And on majority EU table saws shaft diameter is 30mm, not possible to mount 5/8" dados/blades etc.. And second problem will be with small modern saws with autostop (and brush motors), where dados (thanks to weight) doing self unlock from shaft. :)

M hi

7:40 this move is incredible dangerous.