A new zero clearance insert you should see!

[@dunesurfermt5004]

This is probably the best dust extraction explanation i have seen, thanks for sharing.

[@heystarfish100]

I never thought looking at a table saw insert the word beautiful would be in my thoughts. 😍

[@MintStiles]

The world needs more men such as you! Brilliant design and insight into an overlooked system!

[@HookedonWood]

Thanks Cal, Appreciated!

[@michael.schuler]

Incredible analysis, design, testing, and execution. Better than professional.

[@mjg6191]

Brilliant my friend. Incredible explanation of dust control in general with the bonus of an awesome zero clearance plate. Thank you.

[@HODYODesign]

I didn't want to make a zero clearance insert again for my new table saw, precisely because of the airflow issue! I wonder why I never had this so simple but brilliant idea to simply drill holes in it? You made my day, thanks a lot!

[@gadjetsvideo]

Nice design and I love the black MDF, I've not seen that before it looks really nice.

[@jameskirk3210]

Thanks a lot for your kindness. Always a pleasure to hear from you and learn great tricks or gigs.👌👍🖖

[@HookedonWood]

Thanks James, Always a pleasure to hear your comment.

[@Rage-of-War]

The Eddy Van Halen insert.... love it!!! Great idea, yes, patent and sell them!!!!

[@chillu2323]

Love your approach to experimentation and learning. Also: Really refreshing to hear a European accent discussing woodworking in the metric system :D

[@br31woodlands69]

Feels like I am listening to Arnold. Great video sir.

[@kauerpc]

Very nice video! As an engineer, I very much appreciate your thought process and experiments and the use of "turbulence" word!. The sealing/not sealing thing is the same as with olive oil or drinks in a can. With air entrance, it will always flow much better, with a higher flow rate. Thanks for the content!

[@HookedonWood]

Hi Kauer, Thanks for your comment. That you wrote this from an engineer background I like it even more.

[@dustisamust5602]

Very insightful regarding have zero clearance but also letting air in. You exhibit a unique combination of precision thinking and aesthetic vision.

[@HookedonWood]

Thanks for your comment and compliment. Keeps me motivated!

[@BobBlarneystone]

Thank you for your efforts to develop the insert, and your generosity in sharing it. I'll make one. On a different issue, I've noticed in your videos that you prefer black surfaces. Well, I have found that when I got older in age and my vision is not as sharp as it was, that I prefer bright colors. Also, when I've refurbished tools, I paint the inside and undersides a bright color. This makes it easier to see if adjustments are needed at a later time.

[@bladder1010]

This is the most comprehensive and rational explanation of making a good zero-clearance insert. Thank you for taking the time to make this excellent video!

[@Alabamawoodworking]

Awesome video. i've been frustrated trying to get better dust extraction and was trying to basically seal off everything. It never occurred to me that I needed some holes to allow more air flow. This has made such a big difference for me. thank you very much for sharing.

[@londonmaker5347]

Nice update and a fantastic way to show how to make the insert. I love the editing on this. Thank you

[@HookedonWood]

Thanks London, for your comment and positive feedback. Keeps me motivated!

[@davidhuggett9748]

Absolutely brilliant. I haven't got a table saw yet but I'm inspired to make a similar zero clearance insert for my mitre saw :).

[@kenerickson4923]

I made my insert similar to yours. I'll probably make another based on your suggestions. One problem I had was dropping a set up bar into the slot and it falling into a very inconvenient spot inside the saw. Another design of mine was to drill holes at each flange location. I inserted set screws in each hole and could adjust the height of each screw with an Allen wrench from the top of the plate. It's a lot easier and quicker than removing the plate to make adjustments.

[@danielnordstrand6443]

Brilliant! This is real innovation. I myself did not have a thought about holes in the zero clearance throat plate 😅

[@The282mike]

I really enjoy watching your videos! The review of what you like and don't like about the tools you use are also very helpful! keep up the good work and great videos! Mike

[@RichardHurd]

I like your approach to the design process. It is well thought out and methodical.

[@anthonymccall5855]

Excellent design and function; very well thought out. I knew about the airflow requirements for HVLP systems with my router but never gave the tablesaw much though. It always annoyed me that there was a pile of dust in the bottom of my saw (I'm using a two stage system with a 2hp dust collector, shop made Thien baffle and overarm collection on the blade). I made a zero clearance insert (including a hardwood riving knife since my saw predates them) today using your design and I'm very impressed with the results. Way more efficient; this was a game changer. Thank you sir.

[@HookedonWood]

Thanks Anthony, I am very happy to read you like it, and it is effective.

[@TheFalconJetDriver]

I want to add that I made a new, zero clearance insert I added slots on the left side of the insert just like yours and dust collection is better! Thank you. 😁🛫

[@HookedonWood]

Yes, Yes! Good information! Thanks Dennis

[@mikeandrews1508]

Hello Dennis, just found you on KZbin I must say how you come across very professional in your video's and you do not do it on the cheap. Please keep doing what you do best I love your channel subscribed and liked keep up the good work looking forward to your next video

[@HookedonWood]

Thanks Mike, good to have you on board!

[@kentbrowne6974]

Denis, I posted a comment but it seems to have disappeared!!! Anyway, this was the first insert that made sense to me, from an airflow perspective. I made one quite similar to yours, and was going to send you a pic here, but i dont see any way to do it. I made it out of Corian, and it works so well, i really dont need to use my hood on most cuts. Just wanted to say thank you, and that I learn a lot from watching your videos. Keep em coming, as some day I want to start making some videos too, just getting my shop to the point where i can and not be embarassed!!!

[@HookedonWood]

Ho Kent, I know i saw your comment. It was good to read that your table saw benefits from the insert. Good luck, love to see your channel. Most important part is beginning. And when you want to make your workshop better first, welll let that be one of your first videos. All the best. Dennis

[@amrfwws]

This guy is super awesome, I buy a lot of quality stuff. Thanks for saving me money.

[@emmetworkshop2829]

Really good one again. Thank you. I’m jealous of the way you think.

[@HookedonWood]

Hi Emmet, Thanks for your comment. Its motivates me to keep going.

[@RobWhittlestone]

Great work, Dennis! And great research for the best design! Best regards from Switzerland, Rob

[@HookedonWood]

Thanks Rob, appreciate your comment!

[@albertqss]

Amazing. What a great job, buddy! Keep on keeping on! I have just started this new hobby of woodworking and every bit of a great video like yours helps. Thank you!!!

[@fredmandery8620]

Thank you for the great idea. I am dissatisfied with the dust control of my current zero-clearance insert and this seems like a wonderful solution. One suggestion though. At about the 11:00 minute mark you are getting the saw kerf cut into the new insert. You run into the problem of getting the insert exactly in position to cut the saw kerf. Instead of cutting it most of the way through, why not install your dado blade, which usually smaller than the normal working blade, put the new insert in place, move your fence over the insert - not over the blade though - to hold it in place. Then you can raise the blade to cut the kerf. Then you can reinstall the normal sized blade and continue.

[@HookedonWood]

Hi Fred, That is another way. But, I do not have a dado blade. But I find this way much safer and I manage to get the cut right where it needs to be.

[@duster8100]

Dennis, I will comment in the WW forum but the only problem with air entry through the insert plate is there is no air entry when the whole plate is covered. If a drop down shield was attached to the side overhead guard and pulled down on occasions when the cut produces side deflection of the debris then that problem goes away. I think your insert plate is an excellent idea if air can get through it. If I am cutting thin strips I place a piece on MDF on edge beside the blade and the debris deflection does not occur. That is the best demo of why a cabinet should not be sealed that I have ever seen, good work and now a lot more people might understand that sealing a cabinet is the worst thing that can be done. Keep up the good work, your videos are fantastic.

[@HookedonWood]

Hi Chris, I just uploaded the video on the forum. I understand your comment, and you are right that it only benefit if you do not cover the holes. But in most cases, the least thing that can happen is that you get a better ability to clean up your cabinet saw. (before and after the cut) And the insert is an additional hole. Like you also agreed you should not cover the holes from your cabinet. So, when the whole plate is covered, you end up with the same situation you normally would have.

[@BobAmarant]

Wow, very clever. I’m glad I found your channel and I appreciate all the work that you’re doing for the Woodworking community.

[@HookedonWood]

Hi Bob, Thanks for your comment. I really appreciate it. It takes some time to create these video's but it is worth it. Regards, Dennis

[@barstad-9591]

EXCELLENT!!! Thank you for demystifying dust extraction.

[@stufarnham]

Very nice. I really appreciate that you brought an engineering perspective to your build. Thanks!

[@HookedonWood]

Thanks Stu, I like your comment, Keeps me motivated!

[@rudolfpeters367]

Habe viel gelernt über die Möglichkeiten, die Staubabzug zu verringern. Danke - Rudi

[@namelesswarrior4760]

Everything that you do are to the high level of quality.

[@jorgfellinger8004]

Thanks for showing your ideas so clearly. I‘ve got an Axminster sawbench which was verry open underneath. So I closed the gaps under the table to increase the airflow. With my zero clearence insert of alu (4mm) I ve got a peeping sound. So I have to make some changes to avoid vibrations. Your videos are very inspiring. I love them! Greetings from Vienna!

[@HookedonWood]

Thanks Jorg, for your comment and good luck with your table saw.

[@BlackCountryLad]

I really like you very high attention to detail. Excellent videos keep up the great work.

[@RagnBoneBrown]

Fantastic video, learned a lot, thank you

[@matthewhoare6641]

Yesterday I made two of your design ZC Inserts and wow what a difference so thank you Dennis for your great design

[@HookedonWood]

Yesss, good to read😀😀😀👍👍

[@larryohara6513]

I am impressed. Now I got to go back and remake all of my inserts....lol!

[@workshopprojects2643]

Massive thanks to your great vids. I have the same saw and after watching your vids my dust extraction has improved so much. Great idea for the insert I have drilled holes in mine and it has improved it

[@HookedonWood]

Yesss!!! Great to read. Thanks for letting me know. Keeps me motivated. Dennis

[@rickolson9011]

Excellent content and excellent video production! A rare combination indeed! Well done!

[@HookedonWood]

Thanks Rick, Appreciate your comment! Dennis

[@woodfather]

Your inserts are higher quality than my projects! New subscriber, looking forward to going through your channel. 🙂

[@HookedonWood]

😀😀

[@makssootapijten5915]

Appreciate all the work that you’re doing. Keep it up

[@coreywuertz715]

I used a kitchen cutting board and it works great

[@HookedonWood]

Everything that works great, is great!

[@larrybrowning6754]

Nice tip on plugging or opening the gaps on your particular table saw to create the optimum air flow!!! Genius. :-)

[@HookedonWood]

Thanks Larry

[@tonywalls3473]

A guy on the delta table saw group makes and sells them for the delta. It has interchangeable cartridge that so you can set up all the different angle cuts and still have zero clearance.

[@takismantas1159]

When you really love what you are doing then and only then you can take it to the next level. Thank you for sharing.

[@joejaszczak]

Dennis just found your channel and Wow! Great videos and it’s weird to say but that’s a beautiful saw insert. I will be making mine soon! Keep up the informative and high quality videos. Hopefully you can get some more subscribers because people are missing out!

[@tonymckessar5734]

I took a different approach, I use a zero clearance insert, I have 150mm bell mouth sucking out of the cabinet table saw body, but opposite that I cut part of the cabinet open, fixed heavy duty mesh, this allows dust to be easily pulled across the cabinet. I have done this for 6 months and yesterday wanted to change a belt, upon opening the babinet there would have been enough dust to fill a coffee cup.

[@HookedonWood]

In the End, it is the results that count. Nicely done!

[@MechmanGetrieb]

Great Insert! I just finished mine. I´m thinking about upgrading them with your extra slots.

[@garyhorton6652]

Great Demo Dennis, thank you for sharing, can’t wait to get back into my shop.

[@stephendixon8575]

Great idea Dennis. I must confess that I first thought the shallow angled kerf cuts across the top were to allow a little airflow under the workpiece, not just for aesthetics! You mentioned about not putting holes in the right hand side as this would increase friction on the moving workpiece. This got me thinking whether a version made from material with a low friction surface, like melamine faced MDF or phenolic faced ply might be either a way to also allow some air holes on the right hand side or just reduce the friction of your current design. Just a thought ...

[@HookedonWood]

Hi Stephen, My insert does not has that friction on its own. If it has, it is a bit from the suction. And you are right about the cuts across the top. I planed this so it could release pressure to the sides. But, the impact of the suction is very limited because there are enough holes where your dust extractor can get its air from if you cover the holes of the insert. Different then with my router table box. This one is airtight. If I put wood on these suction holes, it is difficult to put your wood over it, that is why I did a sliding door, if it can release the pressure the problem is solved. That is the "normal" situation. So to be short, this is almost a "non" issue.

[@dieterleinen7473]

What an excellent idea! Next weekend I'll modify my insert as well. It's great that you share this with the woodworking community instead of patent it 😃

[@HookedonWood]

Thanks :-)

[@JohnyW87]

Great Idea and really good video.Just inspired me to build one of my own.When I saw the cuts you said they are not necessary,I had the idea for my version to cut them in most used angles for mitercuts 15/30/45 and so on and then just put a strip with same wite of the sawblade to aline the fence more easy for cuts in angles.You inspired me.Thank you

[@HookedonWood]

Hi John, Cleaver idea to cut the angles of the intercuts. Thanks for your comment. I really appreciate it.

[@JohnyW87]

Hey.I’m going to build 2 or 3 for my table saw now and my saw has more space on the left than on the right in the hole.I ordered phenolic resin or pertinax.Is that the material you used for yours?i found coated plywood or “Siebdruckplatte” here in Germany to weak and deformable.But all ready the “prototype” was way better.Thanks again.

[@jamesnasmith984]

Very clear and well presented great idea. PS I love your drill press hold down.

[@terrmaso]

Thanks for the "how to", I believe I was one of the individuals asking for plans.👍

[@HookedonWood]

Yes, you are right!

[@andrehaak1046]

👌 Mooi Dennis, en ook goed dat je tips tussendoor geeft over het veilig werken zoals bij de freestafel met de draairichting van de frees.

[@HookedonWood]

Hoi Andre, Bedankt voor je reactie, leuk om te lezen. Groeten, Dennis

[@brianmills1589]

Dennis, your English is great, my dutch is non- existent. Your videos are great, minor pedantic point, clearance is spelt with an 'a'. Otherwise brilliant!

[@HookedonWood]

Thanks, i know but can not change it. But thanks for your comments

[@joemccarthy9990]

Well done Dennis. I really enjoyed your video on your channel. Tks for sharing with us. I have been a fan . Hope to have my work shop up and running soon. Can't wait to see what you think of your hammer upgrade ☺

[@TylerTervooren]

Hi Denis. I love your insert. It's like a piece of art. What do you think about milling the cast iron top to continue the grooves over to the miter slot? It would be quite an undertaking, but would allow the air to continue flowing when cutting a piece that covers the insert.

[@christofix]

Very interesting video my friend. I will save this video and watch it again later because I'm going to try it on my table saw too. Thank you for sharing my friend!

[@HookedonWood]

Hi Chris, Thanks, watch almost all of your video's and I like them a lot. There is only one thing I think you can improve. Every time I see you use your table saw, this thing is so unstable. That this is the only thing I can mention is meant to be seen as a big compliment. I hope to reach your filming and editing skills someday. Thanks for your comments. Dennis

[@ramongibbs8692]

wow how festinating. But here in the USA those thoughts and designs have been put to practice years ago. still thanks for the video

[@WhoOwl-o4f]

I use a zero clearance insert for specifically for cutting really thin pieces of wood so dust extraction isn’t a problem for me if I’m cutting regular pieces the factory insert is good enough

[@HookedonWood]

When something works good, it works good. But when not, this can be a perfect solution. For me, it was very effective.

[@cwadub]

Can I thumbs up 2x! Great video and design of the insert

[@HookedonWood]

Thanks Chris, Your welcome!

[@whoDatBeDare]

Super smart. Well done. Thanks for sharing. Do you have a vid for dust extraction for your mitre saw?

[@TuanNguyen-iw7yg]

Great idea and really enjoy the content you've shared thus far. Thanks for sharing your great work!

[@texttexter]

Thanks for your update. As soon as i have a table saw i will make this insert!

[@HookedonWood]

Hi Tex, Great to read! I hope it will improve your system as well.

[@KIJs-gc6ux]

Clever thinking, well applicated, good result !

[@weekendwarrior9570]

Excellent video and process. Thank your for sharing.

[@sjeprises]

Beautiful! Thanks for sharing.

[@marcacree809]

Genius, I made a zero clearance insert but of course it keeps the sawdust on top. Will be making some new ones with your ports added.

[@stephanwillemsen8031]

Goeie video's Dennis heel interessant duidelijke uitleg. je werkplaats en de manier van werken en logisch denken vind ik ook heel gaaf, bedankt!

[@HookedonWood]

Dank je Stephan, Erg cool om te lezen!

[@michaell8835]

Superb content Dennis, loving the whole china series, as well as your workshop tours, and builds. Can I ask the make of your table saw, and also the sliding extension, they look really good!? Thank you, from the UK.

[@HookedonWood]

Hi Michael, The brand of the table saw is from Harvey. But I think it is the same as the Axminster Trade table saws from the UK. The sliding extension is also from Harvey. Axminster Trade uses a different one. Thanks, Dennis

[@michaell8835]

@@HookedonWood Thank you Dennis. The sliding extension looks great, I'll take a look into Harvey. Very apperciated.

[@creepyloner1979]

i'd be worried about the diagonal slots potentially catching on the edge of the wood and pushing it sideways or getting chips caught in them that could lift and tilt the wood.

[@HookedonWood]

Theoretically, this can happen. Without the slots, it works perfectly.

[@DocRonSnyder]

Excellent video and cannot wait for your next video. Thank you for sharing your wonderful skills. From your loyal fan.

[@HookedonWood]

Thanks Ron, Appreciate it!

[@jayfoster5756]

Excellent! You have inspired me to make one of my own. Thanks again.

[@HookedonWood]

Hi Jay, I just want to say that I am very happy with your comment. It feels great to inspire people. That is very motivated for me to read. Good luck ad I hope you will be happy with it. Thanks Dennis

[@KlussenMetHenk]

Mooi gedaan Dennis. 👌🏻 Die ga ik zeker nog maken voor mijn nieuwe Festool zaagtafel. Mooi spul trouwens dat zwarte MDF. Thnx for sharing 😉

[@adamdearing918]

Excellent work, information and video! Thanks very much for sharing your ideas 👍👏👏

[@jaykepley5238]

Nice video Dennis. Hope all is well.

[@HookedonWood]

Hi Jay. Yep, everything OK. Nice to hear from you

[@barrydrake6891]

Absolutely brilliant!

[@ldg332004]

I love the relief cuts you made on the top surface of the insert, I assume they are meant to stop the air preasure from your dust extraction system from sucking the work piece down and creating too much resistance .

[@HookedonWood]

Yes, that was the thinking. Of course the wood is sucked to the holes, but that is not a problem. It is not that strong because you should also have some holes in your cabinet. So when all the holes are covered it just extract more air from those places. However, I think it helps a bit. And it looks awesome! :-)

[@RichardHayes]

Thanks for that well thought out and presented build. You've saved me a ton of trial and error.

[@mitchman1155]

Excellent! Thank you for such a wonderful idea- liked and subscribed!

[@art58wong]

My insert uses laminate flooring and has holes on both sides like your first prototype. Then I taped over the holes on the left of the blade. I really like the relief cuts across the top and your way of cutting the kerf then adding a small piece of wood. Well done.

[@TonyNguyenJr]

Looks great!! As I don’t have a table saw or anything I like watching these videos. Have you ever considered the direction of flow for the air inlet? Or adding another small inlet on the side to help the dust rotate from the bottom up into the hose? Just an idea!

[@HookedonWood]

Yes, but i do not want to damage my table saw. So that makes some try and error attempts limited

[@ulrikdhn9838]

Thanks for sharing. Very illustrative 😀

[@HookedonWood]

Thanks Ulrik, Nice to hear from you again!

[@FD-dh2fu]

Beautiful! Great detail. Thank you

[@EntropiaGuitars]

The design is very Van Halen!!

[@cliffgiel7289]

Your videos are amazing. Keep it up!

[@HookedonWood]

Thanks Cliff. Appreciated.

[@pattianctil8703]

Extremely interesting video. I'll be making this for sure. Can you tell me what type of set up you have for your drill press. That hold down looks so effective. I don't know how many times I needed a 3rd arm to best drill a hole. TY

[@HookedonWood]

Hi, that clamp comes with this Bosh drill press. It is indeed a nice system. I do not have the bosh anymore so I implemented a rail in my drill platform where I can slide a clamp in. Works perfect too.

[@billcoley8520]

I just started buying my tools to do some wood working. A complete stranger gave me a craftsman 12 inch bandsaw after he saw my post on Nextdoor Neighbor website. I bought a craftsman palm sander, a Kobalt 10 inch table saw and cheap chop saw. I’m 61 disabled man and my wife wanted me to get off of my butt so she recommended wood working. Do I need to buy a zero clearance insert or just use the one I have? The reason I want to change mine is because this way I can use my drill bits to set my blade height. I can’t use them with my current insert. Thanks in advance.

[@TheMixer1]

Dennis great work as alwasy , See this 100x Need to make one , Has Anyone here in the US found a place to get the Black MDF in small size and not sheet goods . een a smal 15x2o would be enough. thanks

[@HookedonWood]

It does not necessary need to be from Black MDF of course. in fact, I made my first one from MDF and Painted it.

[@TheMixer1]

@@HookedonWood Thank you Dennis I made one yesterday from 1/2 Ply wood came out great , will see if helps m y dust extraction , thank you for making this

[@0katjaanna0]

Great idea... and very informativ video 😍💪

[@ironchefboyardeee]

I wonder if a 3D printed version of this would work, and one could tweak the dimensions to fit their saw. Edit: just checked and my throat plate for Sawstop ICS is too large for a Bambu X1C. Still maybe someone with a larger 3D printer could have luck.

[@KIJs-gc6ux]

Hello Dennis, did you ever check, if your "box" in which the saw is turning is actually so well sealed/air tight, that without your extra air-inlets on top, the airflow in the box is actually insufficient ? Otherwise it could be that the air-circulation under the table influences the airflow of the overhead extractor (and the other way around.), like 2 dust extractors with inlet hoses connected. I made 2 extra inlets in the zero clearance insert and have the impression, that things didn't improve for me if I use both extractors. If I only use the extractor that clears the box, things did improve probably a bit with your additional inlets. I did a lot of thinking about this and came up with the following: I checked my cabinet-box, and found, that there are a few openings in my table and the surface size of these openings seem about to correspond with the surface size of the extractor hose. If you have too many openings (as I now may have) extraction-speed (and strength) are going down quite a bit, so perhaps it is a good suggestion to first check this. what say you ? Best regards, Karel

[@HookedonWood]

Hi Karel, Your cabinet should not be, and probably will not be air tight. It has to cool the motor, but It needs air flow. But of course, you have to check if something is helpful. When I use my overhead dust extractor, I do not find any problem with dust. You understand your point and it was also my thinking. But most of the time, the wood is covering those holes in the inlet, so then the overhead dust extractor gets extra power. So, no extra dissedvantage in that case. Most benefit I get when I want to clean up edges, and cut away small amounts of wood at the sides. And when you can not use your overhead blade guard, than it gives a lot of benefits. SO, in my case I an not find any disadvantage. Dennis

[@mustangk62]

Super job! Heel erg bedankt voor je hulp. Cheers!

[@stephenwalker2195]

Are the slots really only 15mm wide? They look wider in the video.