Page 1 of 2 12 LastLast
Results 1 to 10 of 14

Thread: Home made zero-clearance inserts are a breeze!

  1. #1
    Join Date
    Nov 2006
    Location
    Rochester Hills, MI
    Posts
    940

    Home made zero-clearance inserts are a breeze!

    My TS is an early to mid 70's Craftsman and the insert has a fairly wide slot in it. I looked at the wide variety of zero clearance inserts at Woodcraft but didn't have it my current one with me to compare. I got home and realized I had a nice piece of 1/4" masonite sitting around doing nothing so I decided to put it to work. It was very easy to make the blank and get it to fit. Once it fit, it was just ever so slightly above the table. I put a 1/2" rabbeting bit into my trim router and made a pass around the under side of the insert. I took off less than 1/16". I popped it into place and it fit PERFECTLY! I saved a nice chunk of change and things just got a lot safer working with my TS. I think I'll take the $$ that I saved and buy a GRRipper.

    Click image for larger version. 

Name:	zero clearance 1.jpg 
Views:	66 
Size:	55.4 KB 
ID:	74576Click image for larger version. 

Name:	zero clearance 2.jpg 
Views:	63 
Size:	48.9 KB 
ID:	74577Click image for larger version. 

Name:	zero clearance 3.jpg 
Views:	68 
Size:	68.1 KB 
ID:	74578
    "The bitterness of poor quality remains long after the sweetness of low price is forgotten"

  2. #2
    Join Date
    Sep 2007
    Location
    Plainwell, Michigan
    Posts
    4,855
    Looks good John a GRRiper would sure be nice on the insert, drill a finger hole with a Forster bit, will make much easier to remove

  3. #3
    Join Date
    May 2007
    Location
    Kansas City, Missouri
    Posts
    13,437
    Feels good to save money on stuff like that. I've made mine for a while now. That MDF can be drilled and tapped to put set screws in them for adjusting the height as well. When one gets pretty worn out I'll just make a another and re-use the set screws. I've made them for the older craftsman like you have. If I remember correctly, there is a recess in the table on the back that a nub on the factory plate goes into, which keeps the back of the plate from lifting up. If yours has that spot, I just drilled a small hole in the back and inserted a #4 or #6 nail and cut if off to about 3/16"-1/4" long to hook into that recess and keep it from lifting out. I may have some pics, will look to see if I can find them.
    Darren

    To a small child, the perfect granddad is unafraid of big dogs and fierce storms but absolutely terrified of the word “boo.” – Robert Brault

  4. #4
    Join Date
    Dec 2006
    Location
    Independence, Kentucky
    Posts
    1,354
    Good job John.
    I make mine also for my old Craftsman saw, I used the original plate from my saw to make a mdf pattern, then I use my vacuum pump attached to the pattern to make my inserts with my router table, it works like a charm and you can crank out quite a few in a short time. Cheap and easy to do. I attach a fender washer under the back side to keep the plate from raising up in the back as a safety measure.
    Last edited by Charles Hans; 03-18-2013 at 04:53 PM.

  5. #5
    Join Date
    Oct 2006
    Location
    ABQ NM
    Posts
    30,008
    Well done, John. You're gonna really like the difference a ZCI makes in your cutting, especially ripping thin strips.
    When the going gets weird, the weird turn pro. - Hunter S. Thompson
    When the weird get going, they start their own forum. - Vaughn McMillan

    workingwoods.com

  6. #6
    Join Date
    Aug 2007
    Location
    Reno NV
    Posts
    13,357
    Programmer - An organism that turns coffee into software.
    If all your friends are exactly like you, What an un-interesting life it must be.
    "A door is what a dog is perpetually on the wrong side of" Ogden Nash


  7. #7
    Join Date
    Nov 2006
    Location
    Rochester Hills, MI
    Posts
    940
    Thanks for the input folks. I took my time and made this one fit pretty snugly I set it in place and actually have to tap it down to get it in. Once it's there, I don't think it's going anywhere. When it comes to removing it, the back of the saw is open. I can just reach in there and tap on it a few times with something and it will pop out.
    "The bitterness of poor quality remains long after the sweetness of low price is forgotten"

  8. #8
    Join Date
    Nov 2006
    Location
    Rochester Hills, MI
    Posts
    940
    I just made another one. (for 45 degree miters) I did see that there's a little area near the rear for that clip to catch on. I think that I'll come up with something to engage that lip at the rear. It will keep it safely in place.
    "The bitterness of poor quality remains long after the sweetness of low price is forgotten"

  9. #9
    Join Date
    Jun 2008
    Location
    GTA Ontario Canada
    Posts
    12,247
    cheers

  10. #10
    Join Date
    Dec 2012
    Location
    Bedford, NH
    Posts
    1,683
    Quote Originally Posted by John Pollman View Post
    I just made another one. (for 45 degree miters) I did see that there's a little area near the rear for that clip to catch on. I think that I'll come up with something to engage that lip at the rear. It will keep it safely in place.
    Nice job! Something I may copy on my next TS. Is the insert finished or raw masonite? I think masonite is reasonably stable both temperature- wise and humidity-wise, and probably doesn't need a finish, but not sure.
    Thoughts entering one's mind need not exit one's mouth!
    As I age my memory fades .... and that's a load off my mind!

    "We Live In The Land Of The Free, Only Because Of The Brave"
    “The problems we face today are there because the people who work for a living are outnumbered by those who vote for a living."
    "
    Socialism is a philosophy of failure, the creed of ignorance, and the gospel of envy, its inherent virtue is the equal sharing of misery." Winston Churchill

Similar Threads

  1. Home made I-socket?
    By Ninh Shepherd in forum General Woodworking Q&A
    Replies: 10
    Last Post: 01-06-2014, 03:48 PM
  2. FREE Zero Clearance TS Inserts
    By Jim C Bradley in forum Giveaways, Contests, and Swaps
    Replies: 1
    Last Post: 04-04-2013, 10:27 PM
  3. My Home Made Hollow Rig
    By Wayne Bower in forum Turning Tool Questions and Show & Tell
    Replies: 7
    Last Post: 04-23-2008, 11:12 AM
  4. My First Home Made Tool
    By Pete Jordan in forum Turning Tool Questions and Show & Tell
    Replies: 10
    Last Post: 03-28-2008, 12:09 AM
  5. Home Made Handles
    By Tony Falotico in forum Turning Tool Questions and Show & Tell
    Replies: 15
    Last Post: 11-07-2007, 08:16 PM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •