Table Saw Zero Clearance Insert 

Today, we will be making a DIY 𝐓𝐚𝐛𝐥𝐞 𝐒𝐚𝐰 𝐙𝐞𝐫𝐨 𝐂𝐥𝐞𝐚𝐫𝐚𝐧𝐜𝐞 𝐈𝐧𝐬𝐞𝐫𝐭 for my General International contractor mini table saw. This is a subject that came up several times on social media after my table saw stand video - • How to make a DIY Tabl...
This came about because several people wanted to know if I had made or purchased a Table Saw Zero Clearance Insert for my General International TS-4100. The answer to that is no. I don't think that it makes much sense for a manufacturer to employ R&D times to develop a product that will probably sell for $30~35 for a $100 table saw. It is essential to point out that this applies to many budget-oriented, portable, or contractor saws in the market today. I looked at Ryobi, DeWalt, Ridgid, WEN, and even one from Harbor Freight, one that shares a lot of resembles with mine. All of these small table saw's have one thing in common: the OEM Throat insert is a clip-on. In other words, it is not bolted in place. This makes making a DIY Table Saw Zero Clearance Insert somewhat challenging and the reason why I opted to make an insert for the OEM table saw throat plate rather than making the entire thing from scratch!
𝐖𝐡𝐚𝐭 𝐢𝐬 𝐚 𝐓𝐚𝐛𝐥𝐞 𝐒𝐚𝐰 𝐙𝐞𝐫𝐨 𝐂𝐥𝐞𝐚𝐫𝐚𝐧𝐜𝐞 𝐈𝐧𝐬𝐞𝐫𝐭?
In simple terms, the zero clearance insert is either an attachment or a replacement piece for your table saw's OEM throat plate. It reduces the gap between the blade and the throat insert. I consider this an essential accessory for your table saw because it prevents small stock pieces from falling into the blade well. The throat plate is where the blade protrudes through the deck. It allows easy blade swap from the top and prevents pieces from falling into the saw's blade well. It can also reduce tear-out and helps prevent kickback, which can be dangerous.
While all saws come with a throat insert, these are around all of the saw's capabilities, including miter cuts, dado blades, etc. To accomplish this, many of them have a gap of as much as ½ inch between it and that blade. That is something that is not ideal for fine woodwork. When talking about any Table Saw Zero Clearance Insert and its cost, the top question is always - Do I need one? In my opinion, yes!
𝐌𝐚𝐤𝐢𝐧𝐠 𝐚 𝐓𝐚𝐛𝐥𝐞 𝐒𝐚𝐰 𝐙𝐞𝐫𝐨 𝐂𝐥𝐞𝐚𝐫𝐚𝐧𝐜𝐞 𝐈𝐧𝐬𝐞𝐫𝐭
As previously mentioned, we would be considering just replacing the entire OEM throat plate with a Zero Clearance Insert under normal circumstances. However, our table saw does not quite let itself to that. Instead, we will be making a plate that attaches to the OEM throat plate, giving us the effect of a Zero Clearance Insert while still using the OEM throat plate.
We need something stable at a wide range of temperatures and humidity indexes when it comes to materials. As a woodworker, you may be tempted to make this out of Teak, Sapele, Monkeypod, Mango, Honduran Mahogany, or Purpleheart, but know that when it comes to making a Table Saw Zero Clearance Insert things like MDF, Phenolic, PVC board, and even high-density polypropylene (HDPE) and this was my choice.
The objective of the build was to make a plate insert that bolts under the OEM insert. The first thing we need to accomplish is to create a raised channel about .070 height (the thickness of the OEM plate) by .525 the opening.
To make this, I created a jig that allows me to bolt the polypropylene to it while I safely run it by the saw! It is nothing more than an "L" shape jig where I'll be bolting my piece.
As you probably already saw in the video, the plate is not only not asymmetrical but is also offset to one side. So, that means is that we need to figure out how much is that offset and where does the blade sits within that space. Some type of measuring device a ruler, measuring tape, and even calipers would be ideal but I simply market it with a magic marker and when to work. After mounting the polypropylene piece to the jib and several passes on the table saw I was able to get the insert to fit on the throat plate very nicely.
The next step of to cut it to length, which I did with the miter gauge and fit it into place. I'll be using some #4 by ½ flat head screws for this. I drilled a total of eight holes on the OEM plate on the drill press. I then proceeded to manually countersink all the holes with a carbide bit. I mounted the Zero Clearance Insert onto the OEM throat plate with a screwdriver. It's important to have a feel for when the screws are tight without the risk of overtightening it or stripping it if you use a drill.
With the 𝐙𝐞𝐫𝐨 𝐂𝐥𝐞𝐚𝐫𝐚𝐧𝐜𝐞 𝐈𝐧𝐬𝐞𝐫𝐭 in place, we can now mount it. With the blade all the way down. Turn the saw on and raise the blade slowly to where it cuts a perfect gap on the Zero Clearance Insert. That is it! This project took me no more than an hour and without a doubt, it will improve the performance and safety of this table saw.
#ZeroClearanceInsert #DIYZeroClearanceInsert #ZeroClearanceInsertTableSaw #TableSawZeroClearanceInsert #Ryobi #DeWalt #Ridgid #WEN #HarborFreight #Craftsman #AMAZON #HomeDepot