A new zero clearance insert you should see!

This video is about the H.O.W. Zero clearance insert. It is a zero clearance insert but improves dust extraction.
This is a remake of a video a made 1 year ago, but I want to make it again because in this video I also included how I made it and I share the dimensions.
I also put in some shots so you get a better understanding of the dust extraction inside your cabinet saw.
Nice items I used in this video are:
T-Ruler from "NEW"
www.banggood.com/custlink/DKv...
Drill bit kit
www.banggood.com/custlink/33v...
Tap bit kit.
www.banggood.com/custlink/KGD...
Black MDF
I get a lot of questions about the black MDF. In the Netherlands this is fairly easy to obtain in the hardware stores. Here they call it fully colored MDF.
Valchromat is also a fully colored MDF that is available everywhere. I think this is also very suitable, but it is much more expensive. However, this is a bit more robust, stiff and denser than the MDF I use.
What I use is not Valchormat, but it looks a lot like that. What I use is cheaper and costs around 80 euros here in the Netherlands for a 240 x 120 cm sheet.
I see several manufacturers worldwide who make fully colored mdf. The problem is that there is no brand name here in NL for this MDF. So I find it difficult to indicate which MDF is comparable with this worldwide.
I believe in the USA this could be the same: www.forescolorusa.com
These are the products I use in these video, and where I bought them.
Triton MOF001 Frees
www.gereedschappro.nl/artikel...
Incra freesplaat voor MOF 001 Frees
www.gereedschappro.nl/artikel...
Incra Wonderfence met LS positioner
www.fine-tools.com/routertabl...
Incra T-Track with Shop stop
www.gereedschappro.nl/artikel...
Bosch PBD40 boormachine
www.amazon.de/gp/product/B005...
Festool Kapex KS60
www.maschinenhandel-kimpfbeck...
HBM schuurmachine
www.hbm-machines.com/producte...
Lintzaag Holzmann HBS 245 HQ
www.amazon.de/dp/B00J5ITIHE/r...
Bensch dog cookies
www.amazon.de/dp/B07574FZJL/r...

[@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. 😍

[@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!

[@Rage-of-War]

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

[@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.

[@makssootapijten5915]

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

[@TuanNguyen-iw7yg]

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

[@garyhorton6652]

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

[@RichardHurd]

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

[@RagnBoneBrown]

Fantastic video, learned a lot, thank you

[@barstad-9591]

EXCELLENT!!! Thank you for demystifying dust extraction.

[@gadjetsvideo]

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

[@mjg6191]

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

[@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

[@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!!!

[@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.

[@KIJs-gc6ux]

Clever thinking, well applicated, good result !

[@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 :).

[@larryohara6513]

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

[@amrfwws4461]

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

[@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.

[@jamesnasmith984]

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

[@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!

[@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

[@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!

[@danielnordstrand6443]

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

[@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!

[@Hapyendingwow]

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.

[@adamdearing918]

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

[@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

[@namelesswarrior4760]

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

[@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.

[@FD-dh2fu]

Beautiful! Great detail. Thank you

[@rickolson9011]

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

[@HookedonWood]

Thanks Rick, Appreciate your comment! Dennis

[@chillu2323]

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

[@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!

[@BlackCountryLad]

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

[@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😀😀😀👍👍

[@sjeprises]

Beautiful! Thanks for sharing.

[@RobWhittlestone]

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

[@HookedonWood]

Thanks Rob, appreciate your comment!

[@barrydrake6891]

Absolutely brilliant!

[@mitchman1155]

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

[@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.

[@weekendwarrior9570]

Excellent video and process. Thank your for sharing.

[@mustangk62]

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

[@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!

[@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

[@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

[@rudolfpeters367]

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

[@terrmaso]

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

[@HookedonWood]

Yes, you are right!

[@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

[@br31woodlands69]

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

[@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.

[@larrybrowning6754]

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

[@HookedonWood]

Thanks Larry

[@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!

[@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.

[@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!

[@cliffgiel7289]

Your videos are amazing. Keep it up!

[@HookedonWood]

Thanks Cliff. Appreciated.

[@golfhacker9051]

Great video, well explained.

[@ulrikdhn9838]

Thanks for sharing. Very illustrative 😀

[@HookedonWood]

Thanks Ulrik, Nice to hear from you again!

[@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 ☺

[@woodfather]

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

[@HookedonWood]

😀😀

[@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.

[@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

[@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.

[@albatros1752]

SPECTACULAR !

[@danfoster1935]

Brilliant, Genius!!!! Thank you :)

[@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!

[@HenkKleinee]

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

[@0katjaanna0]

Great idea... and very informativ video 😍💪

[@alindorindicu3732]

Nice R&D!

[@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.

[@MechmanGetrieb]

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

[@jacobbrown1690]

Thank you. My cnc did it perfect

[@cwadub]

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

[@HookedonWood]

Thanks Chris, Your welcome!

[@RicOrnelas]

I like your style.

[@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.

[@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

[@50plymouths]

Very awesome

[@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.

[@RichardHayes]

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

[@fegair1]

Super mooi gedaan!👍

[@HookedonWood]

Dank je! erg leuk om te lezen.

[@coreywuertz715]

I used a kitchen cutting board and it works great

[@HookedonWood]

Everything that works great, is great!

[@jaykepley5238]

Nice video Dennis. Hope all is well.

[@HookedonWood]

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

[@GertVanAssche]

Prachtig! Knap werk.

[@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 :-)

[@whoDatBeDare]

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

[@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.

[@GetHandsDirty]

Awesome, I will be making a few for my table saw :) do you have a digital drawing with the right measurements so I could send my CNC to carve it? By the way, I went over my fence again trying different setups and was able to make it clamp securely without being too tight like we spoke before. So I'm happy with that now. Thanks a lot Dennis and keep up the great work!

[@HookedonWood]

Hi Cris, No, I am sorry, I am an old fashion guy. So no CNC on this moment. Good to hear about your table saw. That definitely should work a lot easier. Nice to hear from you! Dennis

[@mikesibley9339]

Get Hands Dirty hello. Did you ever find or make a cnc file to cut out one of these inserts?

[@jefft7066]

@@mikesibley9339 Each saw model is a little different. I'll make a dxf later this week, but if your saw is different than mine, it might not fit. I hope that makes sense.

[@agblanks89]

@@jefft7066 which saw do you have?

[@EntropiaGuitars]

The design is very Van Halen!!

[@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

[@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.

[@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

[@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.

[@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.

[@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

[@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!

[@philipchung7768]

Your video is amazing, that’s most helpful so far as I’m a newer for this. Btw I have the exactly same size as your shop so I just exactly copy the layout for you. May I ask where can I get the table saw riving knife which is showing on the video as I got the very similar table saw workstation just Axminster branded. I’m struggling with finding the lower one. Many thanks, looking forward to hearing from you.

[@HookedonWood]

Hi Philip, It came delivered with my table saw. No idea if you can buy them separately. Sorry I can not help you with this.

[@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.