How to Make a Zero-Clearance Table Saw Insert

A table saw has a large, oval-shaped opening in the table top, called a throat, through which the saw blade rises up to be exposed to the wood. An insert, often made of wood, plastic or metal, is placed in the throat to fill much of the space around the blade, preventing stock from falling into the saw cabinet. If you use a variety of dado blades on your table saw, you'll want to make a zero-clearance table saw insert to use with your saw.

Tape measure
Pencil
1/4-inch or 1/2-inch-thick plywood
Jigsaw or band saw

Instructions

- 1
  Turn off the table saw and lower the blade below the table top. Remove the insert from the throat of the saw.
- 2
  Measure the distance from the tabs around the throat opening up to the top of the saw table to determine the needed thickness of your inserts. Most likely, a piece of 1/4-inch or 1/2-inch plywood will be a perfect choice. If your measurement falls in between, use the 1/4-inch plywood and some thin shims on the tabs to keep the top of the insert flush with the saw table.
- 3
  Place the removed insert upside down on a piece of your chosen thickness of plywood, and trace the outline of the perimeter of the insert onto the plywood with a pencil. Set the insert aside.
- 4
  Cut the insert out of the plywood with a jigsaw or band saw, following the pencil line as closely as possible.
- 5
  Place the newly cut zero-clearance insert into the throat. The top of the insert should be flush with the table top. If it is below the table top, remove the insert and place some thin strips of wood onto each of the tabs inside the throat of the table saw before replacing the insert into the throat.
- 6
  Turn on the table saw and slowly raise the saw blade. The blade will cut the slot in the insert as it is raised.

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