Free 173 Best Homemade Tools eBook:  
Get 500+ tool plans, full site access, and more.

User Tag List

Results 1 to 2 of 2

Thread: Zero Clearance Insert With Splitters For Table Saw

  1. #1
    Supporting Member tiger carpenter's Avatar
    Join Date
    Nov 2020
    Thanked 49 Times in 20 Posts

    tiger carpenter's Tools

    Zero Clearance Insert With Splitters For Table Saw

    In this video I made 2 zero clearance inserts with the splitters, using very hard iron wood, with very straight grain, which would ensure the inserts staying flat and not warping or twisting over time, especially in the tropics where I live.

    After dimensioning the board, I fine tuned its length on the miter/mitre saw.
    I rounded the corners on the belt/disc combo sander.

    I fine tuned it by hand using the file.

    The deep rabbets / rebates were cut effortlessly on the router table, using a top notch router bit, which has indexable and replaceable carbide blades (please contact info at if you would like to purchase these bits.)

    The zero clearance slot was cut by raising the table saw blade. The zero clearance insert blank was held in place by the table saw fence. Make sure you know where the blade would come out, not to damage your fence.

    The double / twin splitters were made from the extremely hard wood, ancient Asian species, which are even harder than the iron wood. I matched the splitters thickness to 2.7 mm which is equal to the blade kerf thickness.
    I glued the splitters into the slot using ordinary wood glue.

    I enforced the gaps between the two splitters and at the end, using the epoxy resin 3:1 ratio. It really reinforced the zero clearance insert tremendously.

    After the final sanding using battery operated DeWalt palm orbital sander, I applied 3 coats of the boiled linseed oil every week, which made the zero clearance insert waterproof, and very presentable as well.

    I made the test rip cuts using the newly made zero clearance insert, and on the 1.2 meter length, I have 0.05 mm tolerance, which I am very very satisfied with. I couldn't be more happy with the test results.

    The thorough systematic work paid off with the outstanding performance of my zero clearance inserts.

    Now the cutting on my 4 HP table saw feels a lot safer. I don;t even want to imagine a kickback from such a powerful machine.

    Helical Spiral Cutter Head for Makita 2012NB:

    Router Bit Indexable Replaceable Carbide Blade :

    Metal File Kit:

    Marine Grade Epoxy Resin (1/2 gallon) ~ 2 liters:

    DeWalt Palm Cordless Brushless Orbital Sander:

    DeWalt Jobsite Table Saw:

    Grizzly Industrial Sliding Table Saw:

    173 Best Homemade Tools eBook
    At Tiger Carpenter I use both hand and power tools. I put a lot of thought into the design and optimization. I like to come up with the improvements of the tools or jigs that are already out there, and share my ideas or findings with the community so that we all can benefit from each invention.I also implement the principle of aiming for perfection. I learn from the mistakes I made, and I raise the bar for every next project.

  2. #2
    Content Editor
    Supporting Member
    DIYer's Avatar
    Join Date
    Aug 2013
    Thanked 1,676 Times in 1,505 Posts

    Thanks tiger carpenter! We've added your Zero Clearance Inserts to our Table Saws category,
    as well as to your builder page: tiger carpenter's Homemade Tools. Your receipt:

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Tags for this Thread


Posting Permissions

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