How to make a zero clearance insert plate for a table saw with p.v.c.

[@colinsmith7576]

Izzy Swan, great old school thinker, designer maker. Pure American talent.

[@Geoff_G]

This is one of your best and most useful videos. Thanks Izzy, I hope you're doing well these days.

[@tomdenny8507]

What a great idea. I would never have thought of using PVC pipe, ever, but I will now.. Way to go! Thanks!

[@mrmadman1697]

Brilliant, you have given me a first class solution to a prototyping problem that we have, we only want 2 off of some panels and this solves the problem. You deliver the goods constantly.

[@NickFerry]

nicely done Izzy - the last time I moulded pvc in the oven I left it in there a bit long and my wife was not happy - glad you didn't have the same happen - I'm also glad my wife is super forgiving

[@izzyswan]

Nick Ferry LMAO! Been there done that! I diod the same a while back and the house smelled like burnt pvc for 2 days I was in bug trouble.

[@seanmcguire6998]

Why have I not seen this video until now, and why have I not thought of this in my years of upcycling PVC and HDPE?!! This is exactly what I need. Thank You, Master Izzy!

[@UsernameFECKLE]

Awesome!! I just bought a new Delta 36-5052 saw and was considering ordering a zero clearance insert for it, but now I'll probably just pick up some PVC and half inch ply when the saw arrives at Lowe's in a week or two. Thanks, man. This is a really cool method.

[@davidtraugot1405]

I like the info about flattening the pvc pipe, though I'm also concerned about toxic fumes from oven-heating. I think it's a toss-up between laminating plastic to plywood and routing a rabbet around the edge of a solid hardwood insert, as I have always done. Anyway, thanks! And I'm glad that the surgery has literally put you back on your feet. All best, and stay safe and healthy.

[@ayrow69]

Izzy, I make my plates from 1/4" acrylic. The acrylic is exactly the same thickness and doesn't warp or change size. Love the PVC idea. I'll give it a try as well.

[@BenBrandt22]

Had no idea that reshaping PVC like this was so simple. Thanks for teaching me something new. I'll have to tuck this one away for a future project.

[@AustinGriffinUrsa]

Youre the man! I have a table saw with a unique insert plate and its difficult to even find replacements to buy. This will be very helpful.

[@seansysig]

Worked perfectly on my Rigid contractor saw. It took 3.5 minutes @ 350 Upstate NY. Yes make sure exhaust hood is cranking and leave oven door open with fan on until oven completely cools. Leave oven door open for at least 1 hour.

[@Sebastopolmark]

GREAT project Izzy. I have my father-in-laws old cast iron Craftsman table saw and it has the same shallow lip. I definitely will make a couple of these. Zero clearance and dado. Thanks

[@nickoborn]

Always coming up up with interesting and different ideas. So much better than watching what you can make out of arranging pocket-hole rectangles. Keep doing what your doing!

[@kevinslawson8913]

The more I watch your videos the more I'm convinced you are a genius. Amazed at how you make things that id never think of and make them simple. Great job again izzy

[@jakobhovman]

Great workmanship Izzy...as allways...and great video...! The Backer Board...in itself...is a fine solution...for thin inserts...!

[@rb67mustang]

Thanks for this great video. I have a very old Craftsman tablesaw with a very good castiron table. I have never seen the same saw in any video here on KZbin. The plate on my saw is very thin and is held in by a spring clip attached to the existing plate. I've been wanting to make a couple zero clearance plates for my saw and watching your video has given me some ideas that will most likely help me. I'm glad I found this video and I'm now a subscriber as well.

[@vitix5906]

I liked your idea but I think that PVC idea is GOLD!

[@klpittman1]

It only took three minutes to get the pipe to 350° because the ambient air temperature in South Carolina hovers around 200°. If you did this video in August you could have simply cooled the pipe to 350.

[@williamgeorgelopezjunior8533]

Kenneth Pittman that’s funny

[@HyperactiveNeuron]

LOL!

[@bobbg9041]

And solidifying it in cold water?

[@SmokeFlame1]

I have the same saw as you and had a terrible time trying to build an insert plate. You have just solved my problem. Good job, and thanks.

[@WreckDiver99]

AWESOME idea. My table saw is a Porter Cable and it has the EXACT same insert setup...and looking at Dado and Zero Clearance inserts was CRAZY expensive. I'm going to try this!!

[@ldwithrow08]

A great idea!!! I've used 3/4 lnch pvc trim lumber to make featherboards and push sticks but it is VERY expensive and too thick to make good saw plates. I've got a ton of old schedule 40 pvc pipe laying around. My Craftsman saw uses 1/16 plates and finding a good material at that thickness is impossible but I'll try the PVC pipe.

[@norpuma55]

Thanks for the video. I have the exact same saw and I have been struggling with making zero clearance inserts. I am heading to the big box store now for some PVC. Thanks again! I do enjoy your videos and I am a regular watcher !

[@ctpctp]

For those who can't use their oven for PVC, you can buy PVC sheet really cheap. One common brand name is Sintra often used for signage, and Home Depot sells a version called Palight in small sheets.

[@JWAM]

Thanks Izzy! I have this issue to tackle soon. As with everybody else, the biggest issue now is how to insert pvc into the oven unnoticed

[@JusBidniss]

I love the ideas you share! Aside from a zero clearance plate, I've come into possession of an old contractor table saw with outlandishly-shallow miter slots. Fine for the bar stock on the miter gauge, but way too shallow for feeling good about a wood runner for jigs. Flattening out Sched 40 PVC pipe never occurred to me, but that thickness just might work for me! Flatten it, cut strips the width of the slots, and I got runners galore for whatever sleds and jigs I want to make!

[@bmushler]

Double sided carpet tape works well for me. I used two thickness of clear lean I had laying around and hand fit the lower and upper pieces using a hand file. Using the stock depth screws I adjust for a flush fit. Same thing only different. Thanks for the ideas.

[@SteveCarmichael]

Cool idea Izzy! You're an excellent cook! I didn't expect it to get perfectly flat like that. Might make good cnc material.

[@AndreaArzensek]

Steve Carmichael same thoughts here!

[@ballzack57]

Steve Carmichael I make gun and knife holsters out of pvc. It is remarkably easy to conform. It is a thermo-plastic after all.

[@wolfandrabbit]

ballzack57 I feel bad for you that your big creative adventure is a gun and knife holster. Life gives what it gets.

[@ballzack57]

Alec Rix Cool story. I guess I didn't actually earn my royalty payments (in perpetuity) from Intel Corp. That must have been someone else's "big creative adventure" that I am getting paid for.

[@jonq8714]

+ballzack57 *drops mic*

[@ExpatPhil]

Great idea Izzy, I wouldn't have thought of creating a plywood backer!

[@ScrapwoodCity]

Awesome idea! Melting PVC in the oven looks really useful! Thanks for sharing!

[@patcummins6036]

Following you from Australia. Just love your constant use of “THINK” signs everywhere! I’m going to steal that idea!

[@scottwalton4262]

FANTASTIC! I never even thought about using PVC but your instructions about heating the PVC is excellent. Going to cut some up tonight and make them for dado and my box cutting blades too. Thanks BTW Izzy, my 101yr old Dad thinks your a scream... he laughed so hard with some of your projects and it was beautiful!!!

[@stephenmiller6498]

Well I made mine out of a piece of half inch plywood in about 5 minutes works great it's a lot of work for something so easy to make out of plywood

[@outlandishprofessor]

Thanks, Izzy. I've wanted to make a zero clearance plate for my old Delta table saw for a while, but couldn't quite figure out how. Seems simple now.

[@norpuma55]

Just finished the zero clearance insert plate for the Delta saw. Thanks so much. I did struggle with the PVC and I think I will try a high temp in my oven on the next one. Again, thanks so much for the suggestion.

[@AprilWilkerson]

How interesting. Great idea Izzy, I'm going to store this one away for future use.

[@izzyswan]

April Wilkerson Its fun and pvc can be used for all kinds of things

[@jvin248]

izzy swan Look up the videos on making archery target bows out of pvc (BackyardBowyer is pretty decent).

[@user-kw4em9pn4l]

nice job

[@normanelam3561]

? ? Hohhot

[@ArkansasPilgrim]

I need to make 2 of those: 1 zero-clearance, and 1 regular. The insert in my Delta saw has never been flat. One might argue that I should get a better saw, and one would be correct. One would also have to fork over some cash. ;o)

[@deward67]

Wish I'd seen this earlier. I just ordered a zero plate 4 days ago. $35! Grrrr. Thanks for a great tutorial.

[@RealRuler2112]

This is awesome! I have the same type of screwed up table saw insert plate support and unfortunately, they no longer make plates for it. I made an insert plate out of Luann, but it's about 1/32" too thin & every 20 cuts, the wood catches on the back edge. It's also not stiff enough, bending in the middle at the beginning and ending of cuts. One of these is a PERFECT solution and will solve a problem I've had for years.

[@bman1165]

Wow that’s a lot of work, I made my different size guides out of 3/8 Lauan, works great.

[@thejonellwood]

made one of these this morning. great idea!!! also used some of the offcut to make runners for a table saw sled. worked like a champ. thanks again!

[@runfox_4780]

Izzy I love all your ideas, this looks great, and for safety , im sure you added a spliter to this insert plate to prevent kick back.

[@phantom21629]

I bought this same saw. I love it. Was the best investment for my shop

[@ironwood1621]

Is that the 36-725? That’s the one I’m buying.

[@phantom21629]

@@ironwood1621 yes its the 36-725. Still and awesome saw.

[@ironwood1621]

Jamey Larrimore I did a lot of research on saws. I wanted a good saw, with a cast iron table, & good fence (and around $500). This one fit the bill. Delta has an “upgraded” version, the T2, but I can’t find a Lowe’s that has them.

[@jasonminton9681]

Brilliant, straight forward, right to the point, excellent presentation. Just subscribed.

[@SawDustMakerRJM]

I would never have thought of using pvc pipe. Great thinking Izzy

[@russelllindell2509]

Not going to lie, I thought this was crazy when I saw the title and pipe. Glad I watched it, great video and lesson.

[@charleslewis2862]

really timely video for me - it parallels a thought I had after seeing Peter Brown's video on flattening PVC pipe - you have given me the proof of concept and an idea of what I eed to do.

[@jarmstrong2843]

I used a plastic cutting board purchased at the Dollar store. It worked out great. And best part is you don’t need to heat it.

[@pemtax557]

You never cease to amaze me ... who would of thunk it? Sched 40 PVC ... Cheers Izzy, take care of that back!

[@cencalmatt]

Great idea. I have the same saw and tried making inserts with a big hard styrene-like cutting board. Works great once I got it fitted right. Until the summer heat got to it and it sags and is just difficult. I finally just ordered metal plates. For anyone that isn't comfortable making these, the site Tool Orbit has them the cheapest around. Like $38 instead of $56 or whatever it is. In any case, great job Izzy I'll be interested in how those hold up for you.

[@jacktibbetts1337]

Literally watched this video after making a dado insert for my new dado stack. Also wanted to say thank you for inspiring me to get more involved into trying some more non traditional projects.

[@chuckmigrain4956]

OMG, i just tried this yesterday and now i'm telling my grand kids about it... i wan't even properly prepared and it still came ou flat as a board, thanks Izzy

[@JeffSwal]

Thanks for this. I made one for my Delta today. This was an awesome project. Great job!

[@markeagles7383]

I like that’s idea, when you do trimmings, it won’t falls in the gaps. It has happens to me and get jams up and build up, thanks for sharing.

[@joannecoleman2691]

Absolutely fabulous. I will be making this now I know how!

[@frankthornal9489]

Great idea, I have the same saw and have tried a half dozen ways to make a ZC insert. All were failures to some extent. This one I'm sure will work and on my way to get the PVC. Also ordered a couple rolls of the 2 sided tape. Thanks for a great solution to a perplexing problem.

[@cellblock007]

The way u made that pvc board was a great idea. It's a first for me and I think I will be using it very often

[@johnwilcox1302]

Izzy, you are killing it. Keep up the good work.

[@nicracine]

Hey, I'm late to the party, but I've been looking everywhere for an easy way to do this. Thank you so much.

[@MJCPeters]

Izzy, Thank you! at last those of us with bargain saws, can have the safety of a zero clearance insert. I'm doing this Today.

[@jdhurrell]

I've got the same saw and, like April, I've saved this away so I can make some of these in the future. I can't believe it doesn't come with a dado throat plate!

[@Sutoraida1975]

Thanks for bringing Fastcap tape to my attention.

[@Garageworkshop]

Using the pvc was a great idea and I just love the thin strips of wood that you were cutting.

[@RobbsHomemadeLife]

Great video Izzy. I used to make and sell underwater camera housings made from 6 inch sch 80, PVC is under rated, it is a great material. I was not aware of the magnet for holding screws, will look into it. Thanks for making and sharing.

[@Jwalk9000]

Ya know, I thought I had seen all your videos, but this was hiding. Love it. Doing this today.

[@MacnWood]

Amazing! Great idea! I have the ridged saw and making insert plates for it sucks! Ill be trying this out for sure!!! Thanks for the idea

[@Woodgate425]

Excellent idea Izzy. I have been wondering how to make a zero plate went the current one is not very thick. Will give this a go. Cheers, Mike in the UK.

[@dannyh.7490]

Izzy this is a lot of work ! I use Corian or any similar type man made counter top material that you can often get for free. It's just the right thickness or very close so you don't have to do all the back cuts to make it fit down into your table saw insert slot and it's very stable and stiff. Much much easier than all what you've done there with the PVC.

[@glenmckelvey5952]

That's awesome . I've used PVC for knife case's before , but I've never thought of using it for something like this. Heating the PVC in the BBQ work's pretty good to.

[@MichaelHonsinger]

The best tutorial on How to make a Zero Clearance Plate I've seen yet!! Very ingenious, Izzy !! You da Man!

[@irritadad1848]

Excellent! I've got the same saw and have been needing to do this. Thanks.

[@kosinskiarek]

Very good way of using PVC for something that I wouldn't even think of :)

[@josechavez5950]

Thanks! Awesome idea!! I've got a table saw like that, and this is just the thing i need. Cheers from "Chicago"

[@chrishaugh1655]

That out-feed top is trippy.

[@madwilliamflint]

Dude this is awesome. I bought this saw a couple months ago. (Attaching the front and back rail systems is driving me in to the bottle.) I'll definitely be doing this, probably this weekend. Izzy strikes again *\o/*

[@johnanthony2545]

I’m fairly familiar with plastics and heat but this is pretty sweet way to get material when needed. Thanks

[@tonyspigarolo9953]

I go thru these regularly in my woodshop, I buy big sheets of plastic cutting board at a local restaurant shop. I also use the same material to make jig sleds.

[@scottbrooks2351]

Two thumbs up for the part when you said "with a chisel I carefully pried..." Good stuff man thanks for sharing!

[@johnsinclair5465]

Thanks Izzy, this really helped me. I just got a new 4hp 12" table saw and was trying to make a new insert but my saw has a lip all around and my insert could only be 2mm (I think that's 1\16 in your money) thick around the lip.

[@comette4u]

You're a Wild Man Woodworker Izzy! Keep'em comin'!!!

[@josequijada4619]

Love it. Thanks a whole lot. Never thought of the added ply below.. Definitely going to make one.

[@ramaroodle]

Damn you're good with that bandsaw! 😀

[@benb5430]

I made one for my 1990's model craftsman saw using a left over piece of vinyl flooring had to very slowly plane down to fit works way better than my old oak one never thougnt of this might have to try one thanks

[@hinspect]

UHMW would probably work pretty good. We used to call it "the poor man's Teflon". I have bought it from vendor on Ebay and select pieces off Amazon. Thanks for the video, I didn't know it was possible to flatten PVC pipe!

[@yepper1165]

Just a tip relating to that- if you are careful, you can heat up a pvc pipe that's glued into a fitting and remove it. The heat causes the glue to soften and let the pipe come free. It sounds simpler than it is but it can be done.

[@dnngskn62]

Just plain slick Izzy.

[@MrBartoriginal]

The way I make ZCIP is by cutting 1/2" plywood close to size double tape to original plate run on router table to size, making several plates up to this point . Reset router table & rout outer edge thickness to match table top. Drill & screw in allen screws for adjustment. In the matter of a few minutes you can make a dozen up to the drilling & allen screw point. You can also use a UMHW cutting board from ACE & do the same thing. I have both the 1957 Craftsman TS with the thin insert edge & a 1940 Delta Unisaw with the 1/2" thick insert. Another thing you can do is route a slot partially through the plate where the blade comes though allowing clearance for the blade to start its ZC cut.

[@HyperactiveNeuron]

Perfect. I have a table saw with a similar throat plate design. Hate this design but it makes sense from the manufacturing side. I was thinking of making mine with a steel or aluminum cutout for the lip and plywood for the actual saw throat plate. This looks much easier and I wouldn't have to fabricate mounting brackets.

[@vint7054]

Very good, never thought about pvc in the oven

[@JusBidniss]

Very cool, using PVC to get the right thickness between those 4 rests and the surface, yet using the plywood to reinforce the PVC's tendency to flex. I suppose you'd want to not use thicker than 1/2" plywood, and depending on the model of saw, raise the arbor all the way as a test of that thickness, to make sure it doesn't hit the underneath side of the insert.

[@MikeWaldt]

That is a great tip Izzy, and well explained - even I followed it! Take care Mike

[@jonatham35]

That background track sounds like "The Killers - Give Me A Shot At The Night". Love that track and this video! Great job.

[@azyfloof]

I'm amazed how flat you got that pipe! Looked perfect, as far as I could tell 😮😄

[@TheShavingWoodWorkshop]

Very nicely done Izzy, thanks for sharing this one.

[@empace5344]

wow. you have a beautiful and perfect outfeed table

[@allangee]

If you warm up your two pieces of plywood as well, it's easier to get the PVC flat -- it gives you more work time. Otherwise the plywood starts cooling the PVC on contact. You may not want to walk away from the oven with wood in it though! :)

[@williwonka5106]

Nice job Izzy. Best I've seen. I will be replacing my very thin oak plates soon. Thx.

[@twoweary]

Would work as table saw fence sides also. Great idea Izzy !

[@twoweary]

You're right Austin, no need to buy a small cutting and cut it up. I'm sure the list for this idea will get longer.

[@ConstructIcon]

Awesome Izzy! I just got the same saw. I will definitely be giving this a go! I was going to try & use HDPE as well, but this looks a lot simpler!

[@Hutch5321]

Wow! Awesome! Can't wait to try that 'PVC_In_The_Oven' trick!

[@QuackyManSC2]

I have this exact saw (36-725) and I used 3/4 MDF to make my zci plate. I put a slot in the back of mine for the riving knife though. It's a creative idea though.

[@haroldfrench2989]

you can also use a heat gun and heat the pvc up. then use a box cutter to cut the pvc. when no jig saw available. It's cute it like a hot knife through butter.

[@AtomicGeckoBrewing]

I recently did a zero clearance insert but used a piece of lexan (sp?) built the same way as yours but didn't need to melt PVC...also added some countersunk neodymium magnets to help hold in place.