Professionally made zero clearance table saw inserts are an important add-on for any table saw. They make the cuts come out cleaner and ensure small scraps don’t get lodged inside the throat. They are quite expensive though. They run over 30 bucks a piece for my saw. No more, time to make my own. I bought a smallish piece of phenolic coated plywood for 40 dollars. It has enough material to make at least 8 inserts.
I started off trying to make a jig that would hold the plywood and make all the blade relief undercuts and slots for the riving knife behind the blade. It was difficult to hold everything and produced mixed results.
Eventually I just used carpet tape to tape down one of my old store bought inserts. A guide bushing on my plunge router let me remove all the area where the riving knife should be.
From there I printed a 7/16″ radius template for the tracing router bit. I could have used the already taped on insert as a template, but it had a few weird features I didn’t want copied. With a finger hole drilled in, things were starting to look right.
I need a way to level out the insert. The pocket they go in is always deeper than a 1/2″ sheet of plywood so you can raise it up to be flush with the top. I used brass threaded inserts for #6 set screws to give each one leveling feet. The set screws can be adjust from above with the insert in place.
The surface coating on this plywood is hard and very slick. A great material for fences or inserts like this. The phenolic chips like mad though. I will stick with these and have left over material, but probably not buy it again. A few coats of polyurethane and wax would be easier to work with and also reasonably slick.
Because of how high the 10″ saw blade is in the housing I had to use a 8″ dado blade to start the cut before switching back to the full sized blade. I made 4 total, and once I got the swing of things they came pretty quickly. Two will be for dado cuts, so they don’t need the riving knife slot. Hopefully this batch lasts me a few years.
I recently bought an iPad for use during travel and for things around the house. One such thing is for use as a recipe holder while I cook. I have slowly been collecting my various scraps of paper and bookmarks into an organized google drive collection. Most fit nicely on a single page in portrait mode. I needed a way to prop it upright and started with a nice swoopy 3D printed part. I liked the shape, but it was a little too light and the color clashed with my kitchen.
Unusual for me, I built a test piece first. Typically I just launch into this sort of thing head first and start making mistakes. The pine shape was made using the green 3D print as a tracing template. I liked how it came out and proceeded with maple.
As I was cutting the groove on my router I made a huge mistake. I wanted to rout the groove a little wider, and moved the fence closer to the bit to make a second pass. CHOMP!
I forgot, when I moved the fence closer I used the wrong side of the bit. When pinched between the fence and bit, the bit bites in and drags everything forward. I made a little graphic below to show the issue. The bit rotates counter-clockwise. Keep out of the red zone and use the green side.
I recovered by starting over and moving on to a new piece of wood. This time without any issues.
Once I got the groove completed I tapered the back a little. It doesn’t need to be 3/4″ thick all the way across, so I thinned the back end down. I like the effect a lot, but in retrospect I could have gotten a lot more aggressive.
With the tapering done I used the green printed part as a template to lay out the two curved cutouts of this part. I made the center cut wide enough to help lighten the look, and provide a cutout around the speaker ports at the bottom edge of the iPad. I was able to orient the front to show off some lovely rays (little speckles in right hand picture) in the maple.
I am really happy with this, a past version of me would have cut the groove and called it good. The block would have been functional, but chunky and brutal. This is lighter and more elegant. Truth be told I could have done more lightening and still had a functional part, but as always it is a learning-by-doing experience. A spray coat of lacquer sealed the deal.
Two hobbies collide as I print something super nifty for my wood habits. A cool thing you can do with router tables is apply a template onto wood, and use a templating bit to match cut. The bit has a bearing of the same diameter as the cutting edges. It rides against your template and cuts away any underlying wood that isn’t shaped like your template. Super handy, but you need a good template to start with. Enter the 3D printer.
I modeled up this little jig so that it hooks onto the edges of a board and gives an exact radius. It is hard to see given the color, but I printed a 1″ text in the bottom to note the size of the radius.
Here is a picture of the jig fully seated, and what the resulting cut looks like. Very clean and smooth. The large circular cutout gives a lot of finger purchase so you can hold it tight and far away from the spinning bit.
One concern I had was with the material. Would the cutting friction heat up enough to melt the plastic. I did 4 cuts on a 3/4″ bit of plywood and everything looked good. If I had a hundred corners to do, I would worry. I could always upgrade to PETG.
The part is available in multiple sizes on thingiverse
My latest round of cheese boards appeared very successful, but it wasn’t all perfect. I bought a few cutting board templates from woodcraft and was some fun board. For example this pepper below would have looked great red padauk.
The idea is that you double sticky tape this MDF shape down to a piece of wood. Use a saw to cut away most of the excess, then use a flush trim router bit to match the wood to the template. That was the idea at least, it had issues.
Everything was going ok until I got to this thicker area. The bit dug in and shifted the pattern despite all the tape. Ok, no big deal, I just need to go slow, and I can smooth that out on the sander.
Nope. It caught again on the other side and split off a big hunk of the board. This one can’t be salvaged any more.
Things didn’t go well with the padauk, but it some odd grain in places and that shape had tight turns. I decided to try a simpler fish design in walnut. There were no tight spots or harsh curves, so I figured this would work better. Plus I did a good job getting everything really close with the bandsaw.
That looks good, let’s give it a go.
Even with the edges tightly trimmed it still dug in hard and shifted the template. I used a lot of carpet tape, and bought a decent template router bit. No idea what the problem is, but I would issue some caution to anyone wanting to try this for themselves.