How To Make A Zero Clearance Insert | DeWalt DWE7491

[@HowIDoThingsDIY]

I'm looking forward to safer, better cuts with less dust! How do you guys make your inserts? Product Affiliate Links: DeWalt DWE7491RS Table Saw-amzn.to/3wNuVDD Ridgid Jigsaw-amzn.to/3c2wDsT Ridgid Orbital Sander- amzn.to/3vBbUUz Freud Rip Blade-amzn.to/3uxXqUm Countersink Drill Bits-amzn.to/34tlj4y Ridgid Brushless Hammer Drill-amzn.to/3vzGU7w 90 Degree Positioning Squares-amzn.to/3i3xpJK

[@duczman76]

hi would this throat plate also fit for the dewalt dwe 7492?

[@HowIDoThingsDIY]

Yes, I believe it would, but regardless you could definitely follow my instructions in the video to make one for that saw. Thanks for watching!

[@duczman76]

@@HowIDoThingsDIY ok i'll try.i have found some 12.5mm or 1/2" plywood in my scrapbox.the insert is the same thickness.i hope it will work without a router or a bandsaw..i'm a little bit limited with my equipment in my small workshop because i've spend all my savings for my dwe 7492 😅

[@HowIDoThingsDIY]

@@duczman76 I can appreciate that! Do you have a jigsaw and a sander? That would be enough.

[@duczman76]

@@HowIDoThingsDIY yep i have a 10" disc sander and a jigsaw.but we don't like it to work together 😂😂.it's like the dude on the construction sie,who no one wants to work with because he doesn't do what you want him to do anyway.i told him always "just follow the line and nothing else!" but he always ignore my instructions 😂😂

[@davidsettles5706]

Thank you. This is the first video on the subject that addressed the riving knife.

[@HowIDoThingsDIY]

Thank you so much! Ya, I felt the same way, which is why I made this.

[@paulfoote7869]

It is instructive that you showed your mistakes and how you fixed the cracked plate. To keep a forstner bit or other bit from causing breakout on the lower surface of your piece, clamp another board underneath the work. No need to try and drill from both sides.

[@HowIDoThingsDIY]

Good tip. Thanks for the add and comment.

[@rroberts8501]

Appreciate you showing when things DONT go as planned as it adds some reality to the video and of course shows things for others to watch out for. Nicely done.

[@HowIDoThingsDIY]

Thank you. Ya, I try to do that. Something always goes wrong. It's all about how you adapt and overcome.

[@lennytheleopard]

And also how to fix it. Yes well done

[@HowIDoThingsDIY]

@lennytheleopard Yup. Stuff sometimes doesn't go to plan... Haha.

[@frostygill]

Wow. Thank you so much. My favorite part was when you made a mistake and walked us through how to address the mistake. Just incredibly helpful and much appreciated. Thanks!!!

[@HowIDoThingsDIY]

Thank you so much! I really appreciate you feedback!

[@lincolndickerson1293]

Great job, thanks for showing the recovery when the plate broke.

[@HowIDoThingsDIY]

No problem. Thanks for watching!

[@MrKen-wy5dk]

Showing mistakes and fixes makes it real. Great video with creative editing. Thanks!

[@HowIDoThingsDIY]

Glad you liked it!

[@jefferyhaws7565]

Thank you for your very good step by step instructions. I also appreciate the fact that you had a problem but you also had the solution. I've got the same saw and I've watched many videos on making a zero clearance plate for it but I think I like yours the best.

[@HowIDoThingsDIY]

Thank you very much!

[@mr.silverkeys6467]

Just acquired a Dewalt 7491 saw. Will do this as the saw I had prior was old enough to not be able to do a zero clearance. Thanks for the video.

[@HowIDoThingsDIY]

Thanks for watching! Ya, you have to have a zero clearance insert!

[@renoholland7090]

Thank you. I have a saw like that and I'm going to make a plate the way you showed.

[@HowIDoThingsDIY]

Thanks for the comment!

[@rogerbrown5563]

Another short sharp and useful video. I hadn't thought of the dust reduction benefit to. Thx for taking the time and effort to make this video for us all

[@HowIDoThingsDIY]

No problem. Thanks so much for watching!

[@mikeandlucky]

Thanks for the video. I have the same saw, same problem. I bought the Leecraft DW-3 Zero Clearance throat plate for my saw and it is very well made of what appears to be a dense plastic material. However, it does not allow for the riving knife. I tried to add the Microjig Splitter without success as it is a rather complicated installation. After watching your video, I just used a router with a small straight bit to lengthen the saw blade cutout and it works. I know have my riving knife back and I really appreciate the increased safety.

[@HowIDoThingsDIY]

That's great to hear! Thanks for watching and thanks for the comment.

[@howder1951]

Nice work and good to show the weak spot that will surface. I need these improvements on my old saw, thanks and cheers!

[@HowIDoThingsDIY]

You bet! Glad to help!

[@rosefamilypartyoffive8024]

Great job! I definitely need to make one for my new Delta Contractor Table Saw. I have seen so many posts stating that you need a zero clearance for making corn hole boards in order to reduce tear outs

[@HowIDoThingsDIY]

I didn't have this when I made my cornhole boards but it would have been nice.

[@donnachadhaodonovan8960]

Just wondering if you need to use the bolt to keep it locked in place? I have the dewalt 7492

[@HowIDoThingsDIY]

I sometimes fall out when I fold it up, but other than that, it doesn't move much.

[@ErezRaveh]

hey. what is keeping the insert from going up?

[@HowIDoThingsDIY]

Just gravity. But I've never had any issues except when I fold the saw up and put it on it's side. Occasionally it will fall out when I do that.

[@edd.98]

Thanks for this video.i have the same table saw had it for a week been wanting to make a new plate.

[@HowIDoThingsDIY]

You're welcome! I've made lots of stuff for this saw on my channel. I also have plans and blogs on my website. Thanks for watching! Www.howidothingsdiy.com.

[@davidpotts81]

Awesome thanks i started making one of these and realised the plate wouldnt fit in with the blade all the way down i wasnt sure what to do safely. This helped a lot

[@HowIDoThingsDIY]

Glad I could help

[@remcbride2008]

Just got this saw, very pleased with it. Thanks for this video.

[@HowIDoThingsDIY]

No problem! Thanks for watching! If you just got this saw, you may want to check out my video about must-have accessories! kzbin.info/www/bejne/h6Wudndoq7R3Y9E

[@KspaceDoc]

Currently making a new zero clearance insert. Thank you for the help! -doc

[@HowIDoThingsDIY]

Awesome! Let me know how it goes!

[@KspaceDoc]

@@HowIDoThingsDIY works extremely well. Great design and even better tutorial!

[@HowIDoThingsDIY]

@Dr. Patriot That's great to hear! I love hearing my videos help people!

[@siafhir]

Great video. I got the same saw, and I want to make a few inserts: one for the single blade and some for a dado stack I bought. I'll probably make an initial one to use as a template for others, as I'll need several if I want a zero clearance or at least near zero clearance for the various dado widths the stack can do.

[@HowIDoThingsDIY]

Thanks for watching. Next time I make one, I plan to make a few as well.

[@lincolndickerson1293]

I thinking that I have watched several videos about making these 0 clearence inserts. All but one was a friction fit. Every one required “adjustment” screws. What I am wondering about is, is the wood off or are the adjustment screw base pads? Meaning is it possible to somehow make those base pads exactly 1/2 an inch (or whatever thickness the plywood is) from the tablesaw table top. So the wood bottoms out on a positive stop instead. Or are screws adjusting for wood swell? I mean the original plate is metal and it needs adjusted. If it’s possible to build-up the adjustmeant pads then it’s one and done and saves a ton of time over the life of the saw and making inserts.

[@HowIDoThingsDIY]

Interesting thought. I made this a while ago but I feel like the 1/2" plywood was slightly thinner. You could shim it I suppose. But I like the Ability to adust in case the insert shrinks, grows or warps. It's just nice to be able to dial it in.

[@lincolndickerson1293]

@@HowIDoThingsDIY Thanks. I am going between dial it in once or every time. If plywood swells enough to make a difference then what about using a hardwood or material all together. Since the the metal plate that comes with it has adjustment screws I wonder if the top not being made of cast iron caused manufacturing or shipping misalignment that was best solved by end user adjustment. So many fun things to do in the shop.

[@HowIDoThingsDIY]

When you make it, make two and do an experiment to see which method you prefer. I'm sure you know it's difficult to maintain fit of two dissimilar materials. I would think plywood would be more stable than hardwood.

[@lincolndickerson1293]

@@HowIDoThingsDIY I do, I live in the NE now. Used to live in Ohio by Akron for 20 years. Similar season temperature and humidity shifts. I believe some place you mentioned you were in the midwest and sloping floors. It just seems like this is a fit and finish issue. When I get to it I will share any findings with you. :)

[@HowIDoThingsDIY]

Sounds good!

[@richardb.4487]

Nice work. Got my 7491, and planned to make one of these down the road for some thin cutting I'll be doing for a project. But my first project with the saw, I'm using dado, and found that the factory plate won't accommodate the width I want. So I'm interrupting my first project to make one of these for a dado plate. +1 on the kudos for showing making it with simpler tools. And for including the riving knife.

[@HowIDoThingsDIY]

Thanks! I love mine. Much cleaner cuts. I bought the DeWalt throat plate for the dado set but I'll probably make an insert for that as well. Only problem is, you really can only use it for one dado width. Its still nice to have the DeWalt one for general dados.

[@YUSince]

Great Video👍.....very helpful....thank you🙏

[@HowIDoThingsDIY]

Glad it was helpful!

[@j.enriquez]

Hey! Great job! I was wondering - does it do a good job controlling the dust?

[@HowIDoThingsDIY]

I would say it helps the rear dust collection system do its job better. But I still would suggest a general dust filtration system. This is the one I have. amzn.to/3FU2ACD

[@j.enriquez]

@@HowIDoThingsDIY Thank you for the link! I actually noticed a huge difference by simply attaching a vacuum line to the back of the vacuum port of the table saw. I would say - with the vacuum, it can grab about 80% of the sawed wood, but the other 20% still comes from the top of the table saw. Even if this mod can help capture 90% of the sawed wood by the vacuum port and have the remaining 10% come out from the top, I'd definitely try it.

[@HowIDoThingsDIY]

It should help a little more. I think it's always a good idea to have the general air filtration system running when cutting or sanding. Those tiny wood particles are bad for the lungs.

[@HowIDoThingsDIY]

I also use this dust mask whenever I can. amzn.to/3nwghkT

[@j.enriquez]

@@HowIDoThingsDIY - Definitely! I have to use a mask for everything I cut.

[@stevesiefken6432]

Does it reduce the amount of sawdust that otherwise ends up on the table top?

[@HowIDoThingsDIY]

I would say it does help a little especially if you have dust collection.

[@DIMTips]

Excellent video and came out great.

[@HowIDoThingsDIY]

Thanks!

[@mikewinter87]

What table saw blade is that?

[@HowIDoThingsDIY]

amzn.to/48AxOdQ

[@richarddebeer2247]

Great video, thanks for sharing.

[@HowIDoThingsDIY]

Thanks for watching!

[@Thereds-r3h]

What happens when you want to make a 45 degree cut. Do you put the old one back in or make another with a wider recess.

[@HowIDoThingsDIY]

Yup. Just put the old one on for that. Or you can make one for 45 degree bevel cuts if you do that a lot.

[@richardmiller191]

Hey thanks for posting this vid. Great job! Gonna make one today. Too many times I cut a small strip and it gets dropped down the blade slot and then worry about it shooting back in my face!

[@HowIDoThingsDIY]

This should save you an eye! Thanks for the comment!

[@nateswoodcraft6715]

Nice tips 👌

[@HowIDoThingsDIY]

Thank you!

[@timlist4173]

looks pretty

[@HowIDoThingsDIY]

Works even better!

[@kevinash8825]

Hey Travis. I wanted to let you know the audio on your video dropped out around the 8:30 mark and didn't come back until the end of the video around the 9:55 mark. I enjoyed the build though. Great job!

[@HowIDoThingsDIY]

Ya, KZbin didn't like the song I used during that part of the video. I had to do that or remove my video. Thanks for the comment!

[@bazanderson8283]

good job, I got the 7942 (I believe its pretty much exactly the same as the 7941) about to make some myself to accommodate different blades, one question though: what router bit did you use to clear out the middle of the plate on one side? thanks for sharing 🙏👍

[@HowIDoThingsDIY]

That's a good question. I don't remember. You don't need to remove much though, so whatever you have probably will work.

[@paulkc10]

nicely done!

[@HowIDoThingsDIY]

Thanks!

[@Tensquaremetreworkshop]

It is a whole lot easier with a milling machine- which every woodworker should invest in. I made mine out of Corian- strong, rigid and smooth. It turned out flatter than my table saw...

[@HowIDoThingsDIY]

That's definitely a way to do it. I don't even have room for a drill press. Haha. Thanks for the comment.

[@Tensquaremetreworkshop]

@@HowIDoThingsDIY A mill replaces a drill press- does all it can do, and much more. It can fit next to your bench- just move the nail-guns...

[@HowIDoThingsDIY]

Do you have a link to a small mill like this?

[@Tensquaremetreworkshop]

@@HowIDoThingsDIY Depends on the country you are in- there are small 'hobby' mills in the UK from under £500. Not only are they very good drills, you can machine joints, etc not just in wood. I am doing a video on this in a couple of weeks (mills for woodworkers)- will drop a link when it is available.

[@HowIDoThingsDIY]

Interesting!

[@CLPRPSD]

My heart sank when you cracked it with the jig saw. Could see that the vice may have also played a role with it compressed…maybe a router might have been better? I’m just thinking ahead of how to avoid this for when I have to do it. I appreciate your inclusion of this little hiccup in your process, thanks!

[@HowIDoThingsDIY]

Ugh... Mine did too. Ya. It gets thin there. Probably need to just be very careful how you hold it.

[@CLPRPSD]

Btw, this honesty earns subscriptions…and good content of course. *Like & Subscribed* LOL

[@HowIDoThingsDIY]

@CLPRPSD Thanks so much!

[@DSandwich]

Thanks for the video. Any chance you could share the trick to removing the riving knife? It's probably simple, but I haven't figured it out.

[@HowIDoThingsDIY]

There is a release lever on the left side of the table. Take the throat plate off and then pull that lever and the riving knife pulls right out.

[@DSandwich]

Hahahaha. Wow. There's even a sticker with pictures. Thanks for helping a blind guy out. 😆

[@HowIDoThingsDIY]

Hahahah. Don't feel bad. It eluded me as well until I found it.

[@cristian13ytube]

looks great but i think you are not able to fully raise the blade with that... not unless you chop a part of the riving knive, which is not such a big issue since its quite big. thank you!

[@HowIDoThingsDIY]

I'm able to raise the blade about 90% of the way up with the riving knife installed, which has been enough even with a crosscut sled. If you need more you could make the back a slot like the factory one or remove the riving knife for cuts that require full blade height. Thanks for watching and for the comment.

[@willb914]

i need one of those !!!!

[@HowIDoThingsDIY]

Get on it!!!

[@liturgical3d131]

Why not make one of UHMW?

[@HowIDoThingsDIY]

Never thought of that! Great idea. Report back and let us know how it works.

[@TheBonbenk]

Thank you, I'm gonna make one

[@HowIDoThingsDIY]

Definitely. You'll get a much nicer cut.

[@babaloo55555]

Take it from me, friends: do not do what I did and think, "Oh, I don't need to clamp this thing down to raise the blade up. I'll just use a push stick!" or you might end up taking a trip to the ER. (A sutured tendon serves as a magnificent object lesson/reminder that table saws don't just cut-they rotate, which means they can pull you into the blade...)

[@HowIDoThingsDIY]

Great tip! Thanks for the add!

[@ChrisC811]

Brilliant!!

[@HowIDoThingsDIY]

Thanks! Wish I could claim credit for the idea!

[@ginoasci]

use a piece of phenolic use set screws for leveling and install then underneath

[@HowIDoThingsDIY]

All great suggestions. I've become very fond of UHMW.

[@ginoasci]

@@HowIDoThingsDIY : i don’t even know what that is

[@HowIDoThingsDIY]

It super slippery plastic. kzbin.info/www/bejne/fZKQnHt8q7eibMU

[@DonBarthel]

Thanks for not using a jointer, planer, nor bandsaw to make this.

[@DonBarthel]

And thanks for showing us your mistakes so we can avoid them.

[@HowIDoThingsDIY]

You're welcome!

[@HowIDoThingsDIY]

You have to use what you have! That's sort of what my channel is all about.

[@glenschumannGlensWorkshop]

Thanks

[@glenb1972]

Great video to start. A few suggestions: first, don't use plywood. Use MDF. Your insert split because plywood is made up of multiple layers. As you had to mill down those layers, it lost rigidity. Using MDF, which is made up of fibers in all directions, you can mill down and won't lose strength. Second, instead of clamping down that 2x4 over top of your blade, clamp the 2x4 down just to the right of your blade so that it still holds the insert down, but now you don't ruin a 2x4 by slicing a random slot in it. Lastly, set your camera or phone back a bit so you're not having to peek into the viewing range! LOL Good luck on future builds!

[@HowIDoThingsDIY]

Thanks for the great suggestions and for the comment!

[@joeperch4486]

I have been hesitant to make one of these for my saw because every video I have seen is for a different saw and I just didn't want to do all that work only to find hidden "gotchas" in my saw. But I think I have the exact same saw as you. So this might just motivate me to give this a try. Thanks for the video. It was nicely done. One question: is the only thing holding it in place the friction of a snug fit?

[@HowIDoThingsDIY]

Thanks for watching!!! Yes, that's all that holds it in. It's pretty common to do it this way but you could also try to add in a latch. There are other videos that show that part. I just wanted to keep mine simple.

[@steveeymann6374]

I can hear the convo in my head. Where's that damn straight edge? Screw it here's a straight ish stick!

[@HowIDoThingsDIY]

Hahaha... ya, it happens.

[@TylerWardhaha]

bruh wearing slides😆 MY man!

[@HowIDoThingsDIY]

Shop Flops.

[@1122ss]

Thanks for all the useful videos. Now Please loose that horrible boring Bass track background music. Thank you, from everyone!

[@HowIDoThingsDIY]

You're welcome! Would you just prefer sawing sounds when I'm not talking?

[@1122ss]

@@HowIDoThingsDIY Yes. That would be a big improvement!

[@HowIDoThingsDIY]

@@1122ss OK, I'm doing a no talking video now. Maybe I'll leave the music out and let the saws do the talking.

[@1122ss]

@@HowIDoThingsDIY Talking is good, I never mentioned that.

[@sulblazer]

I just remove the fabric.

[@HowIDoThingsDIY]

On the inside? Doesn't dust blow everywhere?

[@uncleronny6748]

I make mine outta the Corian sink cutouts I wrestle away from the lazy af countertop dudes. You don't need to flip the insert over when cutting the fingerhole...just back it with a scrap piece and bore to China.

[@HowIDoThingsDIY]

Hmmm... interesting. Good suggestion on backing the hole. Thanks.