DIY Zero Clearance Table Saw Insert / Choosing the Right Blades

After posting my latest video about my new mobile workbench, many of you have asked me about the zero clearance inserts for the bench table saw which can be seen in the video.
I've made this new video to show you how to use and make new and improved zero clearance inserts to use with the saw, and I'll also showcase the different types of blades I use regularly, such as, for example, dado blades to make grooves.
Plans for this project: bit.ly/3iRfbd9
All Mobile Workbench Videos: bit.ly/3C3gqhV
Zero Clearance Blog Article: bit.ly/3GkM9ML
Saw Blades Blog Article: bit.ly/3Hj1IpE
Where to obtain materials and tools that I use:
Multi-Function Workbench Plans: bit.ly/39eKtrr
Band Saw Plans: bit.ly/2JisRjf
Workbench Accessories: bit.ly/2OSNcKu
Follow:
/ paosonwoodwork
/ paoson_woodworking
/ paoson_woodworking
#woodworking #tablesaw #zeroclearance #dadoblade

[@Paoson_Woodworking]

All Mobile Workbench Videos: bit.ly/3C3gqhV

[@gijssegers]

Well. If what you’re saying is true. You can’t cut without a riving knife. With a dado blade, you are not cutting. You are scoring. Cutting implies separation which is not the case when making dados. Since you’re not cutting, the risk of pinching the blade is significantly lower (virtually zero).

[@TheMrBugio]

Also cmt is an italian company, i think that if they made dado blades they should be fine for eu regualtion

[@isaac_yule]

I appreciate your attention to detail in every project. It’s inspiring. Thanks!

[@Paoson_Woodworking]

thanks Isaac!

[@Daniel-id5kd]

I just ran across your channel looking for insert ideas for my Delta. That’s as clean as I’ve seen yet. I’ve never seen the MDF material you used that’s colored and coated like that here in the states. Your attention to detail is spot on and I appreciate your craftsmanship! Very well done! Thank you for posting this. Subscribed*

[@saxus]

The Riving knife isn't the problem. The problem is with the 10 sec slowdown rule, the weight of dado blades and the way how blades are locked on table saws: In Europe every non-covered woodworking machine (or maybe even metal working machines) must stand down within 10 seconds after you push the stop button. (But in practical it's much shorter). To accomplish this rule the motors have some kind of built in braking solution. If you think about the direction of the nut it is designed to be self-locking and provide constant locking force on the blade while the saw is spinning. Theoretically you're in safe even if you doesn't pull the nut properly, until the blade is standing perpendicular to the shaft. (Obviously, don't try it). However when you stop the saw and the brake is activates a counter-rotating force occurs on shaft. Eventually this - and the momentum of the blade - starts to loosening the nut. For normal blades table saws are designed. Manufacturers calculate how much force have to apply for braking to not loose a properly applied nut. But dado blades have much-much more weight and therefore much higher momentum during shutdown. So dado blades are NOT prohibited in Europe. They're just incompatible with the extra safety functions which have to be built in into a table saw in Europe.

[@ir0ki11er]

There are new dado blade from cmt and they are autorise in Europe

[@saxus]

@@ir0ki11er did you understand what I've wroten? Dado blades never was banned from Europe.

[@mariano_353]

There's a channel, hooked on wood, where the author showcases inserts with holes and slots adjacent to the blade slot for the purpose of allowing dust to be sucked into the machine. Gonna add those too once I start doing mine

[@chrisvanderwielen1530]

I'm curious why you're concerned with making the riving knife work with the dado stack. I thought the purpose of the riving knife was to prevent the separated pieces of wood from pinching on the blade after they pass through. I wouldn't think this would be an issue with a dado since you aren't cutting through the wood, but just making a groove, so there is nothing that can pinch together on the back end.

[@csimet]

Agreed. A dado blade is not meant to make a through cut and only a grove, so the riving knife is useless. Material does not "pinch" when not cut through.

[@Parken26]

Well, he clearly explains it around the 6 min. mark.

[@ipick4fun27]

I was hoping you touch on the parallelism adjustment when you set the blade at 45°. The trunnion is a bitch to adjust on the DeWalt. There is literally no room. My blade was adjusted perfectly at 90° May be .05mm off. But at 45°, parallelism was off by .18mm.

[@Isaiiahii]

We have a lot of the same tools. I have that same table saw, the 12v cordless Bosch router, and I have the 24t and 60t CMT saw blades. Question: does your 60tooth have a high pitch sound when it spins freely? Mine is awful. It's a great blade that cuts really nice, but the high pitch sound is really annoying. I try to use hearing protection most of the time, but sometimes I just need to make one fast cut and don't have any hearing protection on me at that moment, and in those cases, I hate using that 60t blade. But it's only there while the blade isn't cutting.

[@Paoson_Woodworking]

hi Isaiah! it's a bit noisier than the other two blades, but the bench table saw itself makes a lot of noise, even without the blade

[@RickFinch-k6j]

they're only truly zero clearance when you raise the blade all the way up, so you'd actually need different inserts for different heights of the blade.

[@charlesmunday-y2n]

What is the white and dark gray mdf type board are you using for the table inserts and Where in the united states can I buy this product? Charles

[@CzKaa]

Not. In Europe is different problem. Who cares about riving knife? Who cares about regulations? On all Europena saws is possible to easy remove riving knife. In case of regulations/laws this will be technicaly obstructed. Allways using riving knife is only in safety instructions. There it's nothing about laws and regulations. European saws simply haved short shaft for dados use... :D And on majority EU table saws shaft diameter is 30mm, not possible to mount 5/8" dados/blades etc.. And second problem will be with small modern saws with autostop (and brush motors), where dados (thanks to weight) doing self unlock from shaft. :)

[@danijeljelicic]

Hi Thanks for the video :) What size is the hole Ind the dado blade? Normal blades are 30mm for this saw. The reason I’m asking, is that I’m thinking of buying the CMT dado blade stack. It has a 30mm hole. Would that be a problem? Thanks

[@Dean.44]

which table saw you are using what is the modle number please

[@josephromero1596]

I’m looking to do something similar on my Delta 36-441. Has stock splitter that is huge and in the way w attached blade Gaurd - I’m tempted to just re use the splitter but cut it down so I can use micro jig but then I won’t have the splitter/blade Gaurd again in case it doesn’t work out well- any suggestions from anyone?

[@xronisdimopulos4147]

Πολύ ωραίο,συγχαρητήρια !

[@bmz1]

Why would you still use the original insert if he's working less good and precise? Do you have any downside of your own insert? Thanks for your work! Since yesterday, my sled is functional, one week after receiving my table saw.

[@PredragJokic]

Hey there,like very much all your projects. Detailed and well thought. I have question about cmt dado blade set. I daw that when you used full stack that you didn't insert washer is that right? Or there is enough space in order to fit complete dado stack. Best regards and keep greatness going

[@mitsubishmr]

@Paoson Woodworking hello . I order the saw today. What is name this plastic material or you can send some web page? Thnaks

[@PR-WoodWorkingCreations]

It's I guess HPL or you can use HDF I also need to find like this material for the saw

[@Paoson_Woodworking]

I think you won't be able to get it, it was called Compacmel. You can use other materials as it says Praneet

[@mitsubishmr]

@@Paoson_Woodworking Thnaks. And what length Woodworking Enhanced is good for this dewalt 7492 ? 45? 60? cm or 80 cm? And when i order plan for table there is name or links to alieexpres to accesories? for table?

[@squarelevelplumb]

you will need the original if you plan on cutting wood on angles

[@DEADB33F]

Riving knife is only needed when cutting completely through the board. ...if you aren't cutting all the way through then there is nothing to "rive" (split apart), so no safety issue and no legal need for a riving knife. Biggest problem with dado blades is that you need a fairly decent motor brake to stop the additional mass within the required 10-sec spindown time. Many job-site saws won't manage it but any decent full-size cabinet saw should be fine. They'll be designed to work with heavier and larger diameter blades so a small diameter dado stack shouldn't be an issue.

[@sumadimerakai5811]

Pekerjaan anda sangat sempurna. Saya sangat senang melihat video anda. Sy hanya bisa bermimpi bisa bekerja seperti anda. Padahal kayu di daerah sy masih berlimpah. Sy di pedalaman Kalimantan. Indonesia

[@giorgiialikhanashvili2818]

Hi! I have a question about saw blades. Their thickness is 1.6 mm, the width of the cut is 2.3 mm. The thickness of the wedging knife is 2.2 mm. Do you ever have a knife stuck in the cut?

[@wurkinaround]

Hi, I bought the same DeWalt saw, I'm in Europe. Two questions: are CMT blades with think kerf really compatible with the standard riving knife. Don't you get a slight misalignment since the kerf is thinner than on standard blades? Would a 254mm (10") blade also work or is it too wide? Thanks for you reply and I love your amazing work by the way!

[@DanielFlores-os9fr]

Great video as usual from your chanel. Thanks for sharing, by the way, what if a "Driving knife" can be modified with different thickness to match dado blade? using same metal to insert and hold it in place, but modify the thickness in order to keep a level of protection?

[@vitfedorchuk]

Thank you for the detail demonstration. I've just an insert following your experience)

[@Tukangkayu_ae]

terimakasih sharingnya pak

[@enzopei940]

Hello hello, love the video as always! And routine time: Fence～Fence～Fence～ Hahaha

[@richardc6932]

Nice inserts but I don’t understand why you run that blade higher than needed or recommended.

[@gandalf1124]

There is no requirement in EU for a riving knife when making non trough cuts. It's fully acceptable to remove it as it will serve no purpose if it's with is not matched to the blade. The only limitation to dado blades I can find besides what you menthion about being able to mount it securly is a recomendation to use a shaper instead for production runs.

[@Paoson_Woodworking]

thanks! I had understood that you cannot work with the table saw and Dado blades without the riving knife, have you found any official document that explains this better?

[@gandalf1124]

@@Paoson_Woodworking The documents I have found are in Danish, and it has been a while since I looked into this.

[@ir0ki11er]

They are new dado blade from cmt and it's autorise in Europe

[@elvisoshaughnessy4109]

Hello there, 1st time I've seen you using double blades on a dwalt table saw, is it possible

[@geraldordelt2334]

What material do you use for the Zero Clearance Table Saw Insert?

[@Paoson_Woodworking]

"Compacmel" www.paoson.com/blog/en/bench-saw-and-boards-for-the-mobile-workbench/

[@antoniodonofrio2986]

I would be interested to buy your Z-clearance inserts…you could realize and sell a set to me?

[@MrMutzikatzi]

Thaks a lot! Especiallly the tip with the washer in the back to secure the Jig is great!!!

[@davekrueger]

Excellent video. I made that modification to the riving knife on my Dewalt to allow the throat plate sides to be connected at the rear. That knife is made from some tough steel. I wrecked two metal cutting jig saw blades trying to cut that notch and made no progress at all. Instead of knife, they should call it a riving katana. Anyway, I finally just ground it down with a bench grinder, filed it smooth, and painted the bare edges with a paint pen. Took about 10 minutes max. That mod is a great idea, but it would never have occurred to me, so thanks!

[@THS2615]

The manufacturer is not recommend using the Dewalt table saw with dado blade, but i want to use it after having a Workbench for my table. Can you share your experience while using dado blade with dewalt saw?

[@Paoson_Woodworking]

hi, the DeWalt DWE7492-QS allows you to use small diameter dado blades without problems, I use it almost every day: www.paoson.com/forum/viewtopic.php?f=22&t=59#p6159

[@THS2615]

@@Paoson_Woodworking thanks for the feedback!

[@mariano_353]

Es justo lo que necesitaba. Tengo que renovar el inserto de mí dw745. Y estos son geniales

[@MathiasLeth]

Would you be interested in selling me two inserts? I live in Denmark

[@viljarm]

You could get away without "shaving" the riving knife if you leave a lip that goes below table surface. Look at the original insert plate, there are two small tabs. I believe there is enough room to have the lip entire width from tab to tab position and make it even longer. This way you can have your groove for riving knife go a bit further without breaking the insert plate. You have to engineer a locking mechanism similar to original in front though but there are plenty of alternative designs in youtube for that.

[@clydedecker765]

Where I live, there aren't any of those types of wood available within 200 miles. Even then its an "Iffy" proposition. Melamine coated colored MDF is unheard of even in search engines here. MDO is a plywood used for road signs in highway departments. Specially made. Usually not available except by special order with LONG waits. I absolutely LOVE your designs and their look. Practically none of the material you use is available and it would be cost prohibitive to say the least. Hooked On Wood makes similarly ingenious designs --- in the Netherlands.

[@Karatikus]

Try searching for „HPL“. Don’t know where you come from, in Austria is a manufacturer called FUNDERMAX. Maybe this will help you to find an equal manufacturer in your area.

[@louis3141]

Are you in the United States? & Yeah Dennis from Hooked on Wood is amazing! His new shop is looking good.

[@desertpillar5286]

I've been searching for the same with no luck in Sweden. The best I've found and bought so far is Valchromat, which is not only colored MDF but also much higher density and behaves more like hardwood. But getting it melanine-covered opens so many possibilities. Hoping that I can convince some importers here to make it :)

[@TheMrBugio]

@@desertpillar5286 Valchromat is an awesome material. You can easly coat it with melamine with some contact cement. Anyway HPL is not the material is a special kind of melamine made of resin soaked paper. I suspect the material he's using is some kind of HDF like valchromat coated in HPL. Pricy but extremely durable.

[@dagsekkester2175]

I think the material he is using is CompacMel made by the manufacturer Finsa in Spain. It is similar to MDF but made too much higher density. When std Mdf 12mm is typical around 770-800 kg m3, CompacMel is close to 1200kg m3. If I remember correctly 😅

[@jimlad01]

Fantastic stuff as usual, thanks very much Paolo. Have you not felt the need to shorten the height of the riving knife?

[@ozguzzi]

You have a CNC router, why not make the whole insert on it?

[@wolffritsche]

Hi, absolutely addicted to your videos; that is my dream workbench. I can't find the link to the plans for this bench - can you please provide (in Messenger if you prefer)?

[@Paoson_Woodworking]

bit.ly/3iRfbd9

[@benoitvos]

Dear, I wonder if you change the original bolt to tighten the blade ? Also, did you ever encounter any loosend blade using the dado stack? Thanks a lot for your answer

[@Paoson_Woodworking]

hi Benoit, it is the standart bolt. You will not have problems with the Dado stack if you use it properly!

[@tool_box1715]

Что за материал использует, кто подскажет?!)

[@cesargamez7384]

Magnífico maestro es usted genial de Aguascalientes México Francisco gamez un abrazo muy fuerte y saludos cordiales bendiciones para usted y toda su familia 😯👍👍👍👍👍👍👍👍👍💯

[@Paoson_Woodworking]

gracias César!

[@AWWoodworks]

What DeWalt saw are you using? Does it comes standard with a 250mm blade?

[@Paoson_Woodworking]

www.paoson.com/forum/viewtopic.php?f=22&t=1940

[@bradleytuckwell4854]

One of the best inserts I’ve seen built your attention to detail is always on point thanks for sharing

[@mr.hurley217]

Excellent video on zero clearance inserts. What model of Dewalt table saw do you have?

[@Karatikus]

7492

[@luigi33z_]

Hi Suso have you a link of dado blades?

[@tizianomanca2111]

beautiful and useful video, congratulations. but I can't figure out what material you use for the final piece. I cannot recognize the gray material you use for many processes. maybe i missed his name. could you tell me? thank you very much.😃

[@Paoson_Woodworking]

www.paoson.com/blog/en/bench-saw-and-boards-for-the-mobile-workbench/

[@tizianomanca2111]

@@Paoson_Woodworking thanks for the explanation, I missed it

[@timpedzinski230]

You can also cut the blade groove through the thick MDF using a saw blade of a smaller diameter mounted on the saw. Just make sure it is the same or smaller width.

[@Paoson_Woodworking]

right! thanks Tim

[@pjhalchemy]

Excellent tutorial and sequencing to build quality Z-clearance inserts. Like your washer lock system! Thanks very much for all your great video work, with excellent designs and fabrications!!

[@Paoson_Woodworking]

thanks mate!

[@gabegarza6780]

Very precise thanks for sharing

[@elianele5643]

I had learned👍

[@Isaiiahii]

You are amazing! You are a true perfectionist.

[@michelebenini8125]

Very compliments 👏🏻👏🏻 what is the model of the saw?

[@Paoson_Woodworking]

Dewalt dwe7492-qs

[@michelebenini8125]

@@Paoson_Woodworking thnkx a lot!!!🙏🏻

[@michelebenini8125]

@@Paoson_Woodworking scuse me .., and the material of zero clearance is a mdf or phenolic ?

[@Paoson_Woodworking]

Compacmel, it’s similar to MDF, but more compact and tougher. You can also use DM perfectly.

[@raptorbudanov1752]

What machine you used????

[@nicecondo1196]

What is the name of this high density MDF w/ melamine?

[@Paoson_Woodworking]

check this out: www.paoson.com/blog/en/bench-saw-and-boards-for-the-mobile-workbench/

[@benoitvos]

Dear, thx again for your videos ans plans. I'm nearly done with the build of my mobile workbench based on your plans. I've bought the same blades as yours but saw that the riving knife of my saw (same of your dewalt) is mentioning that it allows blades above 1,5mm kirf. The ones we have are 1,4mm. I wonder if it was a problem for you ? Aren't the pieces of wood thightend vu the knife against the fence ? Thanks a lot for your answer

[@Paoson_Woodworking]

hi mate! my CMT blades are 2.4mm thick, are you sure yours are 1.4mm? I would love to see pictures of your mobile workbench, you will find my email at the bottom of the web

[@benoitvos]

@@Paoson_Woodworking sorry, yes 2,4mm as well. But on the knife it is indicated that it s for blades that are at least 2,5. I think i should tune the knife because with the caliper it's at 2,2. It should work but my wood pieces seems to be hard to push at the end of the cut

[@Paoson_Woodworking]

I've been using the CMT blade and that knife for months and I haven't had problems. What I do remember is having to adjust the knife to align it, I used masking tape to separate it a bit to the right, I think I remember!

[@Paoson_Woodworking]

now that you mention it, it seems tight, I have to check it again

[@Ndhomewood]

What table saw is that please?

[@josephpardo239]

How do you keep your tablesaw so clean under the saw blade?

[@DEADB33F]

The whole shop looks like it's never been used for production woodwork. ...look how clean the drawers are @ 0:50 I bet the guy doesn't even have callouses 🤣

[@pauloalbertovamosfalardequ6976]

Thanks my friend!

[@bashir1323]

Excellent wow !

[@patricksimons560]

Great work again!

[@kneck84]

Also trying to find a similar material. What would it be called? HDF + Melamine?

[@Paoson_Woodworking]

not exactly the same, but would also be perfect for this

[@Karatikus]

HPL…

[@LostWhits]

HPL and Compact Laminate.

[@wiseoldfool]

Possibly HMR (High Moisture Resistance MDF).

[@kenluning909]

Real nice video on table saw inserts. Thanks.

[@Paoson_Woodworking]

thanks Ken!

[@firdoshmody]

M hi

[@equalibrium7898]

Class, pure class

[@АлександрВладимирович-к2р]

Работа просто супер 🔥💪👌👍

[@PR-WoodWorkingCreations]

*First* 👍🏻

[@coolruehle]

I wish I could find this 13mm material in Texas. I have had ZERO luck locating anything like it.

[@marcelo403polo2]

In Alberta also no way to find something like that

[@Paoson_Woodworking]

:D you can also use HDF or MDO board with melamine

[@marcelo403polo2]

@@Paoson_Woodworking what is MDO boards. HDF is available here, but w/o any melamine on it

[@Karatikus]

Elevator manufacturer (OTIS, THYSSEN…) use that material (HPL) often for the inner surface of the cabine. At least in Europe..

[@marcelo403polo2]

@@Karatikus LOL. Maybe they also use it in elevators in north america. I hope you dont suggest here that we should just take some elevators apart to have material for zero clearance inserts etc. LOL

[@ohasis8331]

Nicely done.

[@luismariano001]

Amazing

[@muhammadnaseem4339]

Prize kiya he

[@PR-WoodWorkingCreations]

*Great Video!! Definitely going to Build this for My Saw* 🌟👍🏻 *I also Bought the same Table Saw but I didn't get a default Blade in it and I need buy all 3 but don't know which brand blade to buy coz in India I'm only getting 80t DeWalt Blade but not getting 60t and 24t so can anyone suggest which brand blade should I buy in India??* *And I have a 10" Miter Saw Blade and when I put it in my saw there is a difference in blade and riving knife how do I adjust it?? If I could attach photo it would be better to understand*

[@mitsubishmr]

@PRANEET BANE CMT blade isn t in India?

[@PR-WoodWorkingCreations]

@@mitsubishmr I searched in Amazon India and I got but non of their products were in stock and + if in stock it was unable to deliver to my location ☹️ I'm searching for CMT delear currently

[@mitsubishmr]

@@PR-WoodWorkingCreations i Can help order in our country and send you

[@PR-WoodWorkingCreations]

@@mitsubishmr but how much it will cost?? Coz importing will cost more I guess And How you can help?

[@mitsubishmr]

@@PR-WoodWorkingCreations I think i help you. I order in me country shop and send you. Now a check and when i send up to 500g it cost 6€

[@mvmc1607]

Top....

[@erichschmidt6144]

Super Arbeit 👍👌🙋‍♂️

[@TheFlightstick]

❤️

[@playboxxtv6287]

7:40 this move is incredible dangerous.

[@woodworkingfevermore6826]

Not sure if I missed it. but what is the new zero clearance Insert material made out of? Otherwise great video thank you

[@Isaiiahii]

He said it is a high density MDF with a laminate.

[@woodworkingfevermore6826]

@@Isaiiahii oh. Ok thanks

[@Karatikus]

HPL

[@viorsa8200]

Excelente tutorial cómo siempre , un trabajo impecable , gracias por compartir tanta información y conocimientos , un saludo cordial y por supuesto un gran like desde Narón (Galicia) 🤓 🛠️ 🔝

[@Paoson_Woodworking]

gracias como siempre compañero!