How to Make a Zero Clearance Insert Plate for the Dewalt Table Saw

🔧A custom zero clearance insert plate can prevent small pieces of wood from falling into the table saw gap and improve safety.

📐By creating a custom insert plate, you can ensure a tighter fit to the blade, reducing tearout and improving the accuracy of your cuts.

⚙️Use the original throat plate as a guide to determine the size of the wood needed for the custom insert plate.

🔍To create the blade gap, use the original plate to mark the cutout and carefully remove the excess material.

🔩Secure the custom insert plate with screws and adjust them to sit flush with the surface of the table saw to avoid any obstacles during cutting.

Why is a zero clearance insert plate important for a table saw?

—A zero clearance insert plate helps to prevent small pieces of wood from falling into the gap around the blade, reducing the risk of kickback and improving safety.

Does the custom insert plate improve the accuracy of cuts?

—Yes, by creating a custom insert plate, you can ensure a tighter fit to the blade, reducing tearout and improving the precision and accuracy of your cuts.

What materials do I need to make a custom insert plate?

—You will need a piece of wood that matches the size of the original throat plate, screws for securing the insert plate, and woodworking tools for cutting and shaping the wood.

Can I use alternative materials instead of wood for the insert plate?

—While wood is a common and easily accessible material, you can use other materials such as plastic or phenolic if they are compatible with your table saw.

How often should I replace the insert plate?

—It is recommended to inspect the insert plate regularly and replace it if it becomes worn or damaged. However, with proper maintenance and care, a well-made insert plate can last for a long time.

00:00Introduction: The creator is annoyed by wood debris falling into the gap of their table saw, so they decide to make a custom zero clearance insert plate.

00:09Step 1: Remove the original throat plate and use it as a guide to determine the size of the wood needed for the custom insert plate.

00:23Step 2: Mark the cutout for the blade gap on the wood using the original throat plate as a guide.

00:31Step 3: Remove the excess material to create the blade gap using woodworking tools like a router or a jigsaw.

01:09Step 4: Ensure a tight fit by shaping the edges of the custom insert plate to match the curve next to the blade.

01:34Step 5: Test the fit of the custom insert plate and make any necessary adjustments.

02:08Step 6: Secure the custom insert plate with screws, ensuring they sit flush with the surface of the table saw.

02:33Conclusion: The custom zero clearance insert plate prevents wood debris and improves the accuracy of cuts.