Table Saw Zero Clearance Insert, How to make one and Why you need One!

In this video I make a zero clearance inset for my Bosch table saw.
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[@jackpine4347]

This is great. Helpful if you have a thickness planer and a bandsaw to make quick work of it. Will need to try re-sawing using the table saw and then a jig saw. I guess once a good blank is made that fits well it can be used as a template for the final shaping with a router.

[@myerscok]

Thanks John, your video has inspired me to make one for my saw.

[@ohallifax]

Thanks for this - just got this saw and making my own zero clearance inserts is definitely something I want to have a go at!

[@user-yw5fj4je2c]

Thanks Master for the good ideas. I will try to make it with your help.

[@I-Love-Taylor-Swift]

70% of viewers are not subscribed? Come on people! Of all the woodworking channels I like & watch on KZbin, I always think John McGrath is probably my favourite. I am subscribed and "notificationed" (is that a word?) 🙂

[@JohnMcGrathManInShed]

Nice of you to say!

[@paulbrennan9193]

I think the same could be said for alot of woodworking channels, the American channels have a big advantage in this regard. Top 2 woodworking channels in my opinion are Irish based

[@Putzickle]

I couldn’t agree more, love this channel 👍

[@lendevonuk5479]

I watch quite a lot of American channels, and mostly they are first class, but well subscribed! John’s channel is up there amongst them, probably in the top five (in my humble opinion), so come on let’s give our own man the support he needs!! Len (Devon 🇬🇧)

[@projectrebuild908]

Nice simple one but the upgrade to potential safety is massive. Thank for this one.

[@JohnMcGrathManInShed]

You are welcome

[@SuperMicroguy]

Nicely done! A very thorough explanation. I hope my attempt turns out as well as yours. Thank you.

[@stephb8178]

Gonna make one for my new saw, thanks, StephanieB

[@ladykenja2700]

- Thanx a multimillion for sharing your skill & knowledge. This was extremely useful & clear.

[@shed-guy]

I like the way you cut through the middle just short of the end, I never thought of that good thinking, I'm gonna make a few new ones and yes I always use a riving knife.

[@three-phase562]

Great little project for a table saw, thanks for sharing.

[@JohnMcGrathManInShed]

Thanks for watching!

You've created a beautiful new cover. thanks for the details.

[@Pmobley47]

Thank you!!

[@JohnMcGrathManInShed]

You're welcome!

[@keesvlasblom8091]

Nice work

[@samtheman0876534]

Great video john👍 thanks for all the helpful information you share

[@JohnMcGrathManInShed]

No problem Sammy

[@Annaisineire]

Great video John, welll done!!!

[@alistairbiggar6830]

Another great video John, thanks 👍🏼

[@JohnMcGrathManInShed]

No problem Alistair

[@andrewknots]

Great build, thanks for sharing. I think that you could have routed out the four support points,same as the ledge on the left, rather than thinning the whole insert, and thus get a slightly stronger insert.

[@MCsCreations]

Really nice work, John! 😃 I definitely need to make the same for my table saw! Stay safe there with your family! 🖖😊

[@johnbrooks1422]

Good idea I will make one brock mine Great Video Thanks

[@blackbeton3923]

Really good job

[@JohnMcGrathManInShed]

Cheers

[@conorlavery4762]

Hi John...... looking forward to watching this one later - staying out to soak up alll the sun for now...... 🇮🇪 🇮🇪 🇮🇪 😎

[@JohnMcGrathManInShed]

Enjoy!

[@jonasmoqvist5133]

Nice work! 👍

[@JohnMcGrathManInShed]

Thanks! 👍

[@budlloyd3127]

another great video! I gotta make a new insert for my table saw. I've got the old craftsman 113 ones, they've got no riving knife so I just have to glue in a bit like you were saying. I'd love to see you make the zero clearance for your miter and bandsaw as well! fun little projects lol

[@Realism91]

I've made mine with this through cut method before, mine was for the dewalt compact table saw from baltic birch and the narrow side is 1-1/8" 28.5mm it warped the narrow side is higher than the wide side... I recommend drilling for a dowel before shaping if it's a elongated circle after fitting it and cutting the kerf put the dowl in and it'll stay aligned... Always harder to say something than to show it.

[@leehenderson8488]

Great Video John. Ive got the same saw and been meaning to do this for a long time. Think you may have just pushed me to make the effort. I have put my router in the extending wing of the saw, not something you need as you have the router covered but a board that drops in the wing is useful support.

[@keggyification]

Hi John, I have the same saw as you and find a constant issue with the blade height adjustment not allowing the blade to withdraw completely into the saw base and it's always down to a build up of saw dust on the guide rods of the lift mechanism despite having good extraction on the saw every time I use it. I find myself turning the saw over at least every other week and cleaning this debris out with a bradawl and shop vac which can be quite fiddly. I like the saw generally but find it a little underpowered at times especially if the blade is starting to go dull. I have a zero insert just like yours made in pretty much the same way just out of some marine grade ply that I had in the shop and wouldn't want to use the saw without it. I seldom bevel the saw so just switch back the factory insert if I do but you're right that this can leave little to no support for the work piece at time so maybe I should stop being so lazy and make a sacrificial one for bevel cuts as well. Thanks for sharing your skills once again.

[@tomdickson9075]

Nice, love the videos and was hoping you'd do a video on this as I've just got the same table saw

[@JohnMcGrathManInShed]

Nice! hope it helps

[@DirkieB]

Nice, keep ‘em coming! I’ve got my axminster (craft) table saw and need to make all these jigs! Even a bigger and better crosscut sled. But where to find the time!!

[@JohnMcGrathManInShed]

Will do ! some many jigs so little time 😀

[@lendevonuk5479]

John you are a ‘born’ natural! Love your video’s which are always very informative, precise and yet relaxed! Not bad for a ‘red headed’ Irishman! More ‘stuff’ please!! Idea: finishes; waxes: polishes, spray guns etc. 🧐 Cheers Len (Devon 🇬🇧)

[@lendevonuk5479]

Yes….John is brilliant!! Use him or lose him, and we don’t want that!!!

[@JohnMcGrathManInShed]

Thanks Len. I'm glad you like the content

[@xsbxsbxsb]

Thank you for sharing, John! Would you consider adding slots parallel to the blade for dust extraction?

[@JohnMcGrathManInShed]

Maybe some extra holes could work, slots may cause the insert to flex, but it's worth experimenting with

[@roydaley3413]

👍

[@JustavvaGo]

Great share. Do you think that Bamboo or plastic would be a good alternative to the wood that you used?

[@thomasmcglynn5353]

As all ways a great video. Have to say you have a good way of explaining how to do something. Can I ask did you do the draw for the sharping plats yet ?

[@JohnMcGrathManInShed]

Not yet. I will next week

[@thomasmcglynn5353]

@@JohnMcGrathManInShed no worry’s I was just wondering did I miss it. Enjoy your weekend hope you have it to yourself

[@cunnie74]

Great work as always John. What router are you using that you can change the bit without using any spanners?

[@JohnMcGrathManInShed]

Hi Pat it's the Sauter router made by mafell

[@psourial]

Hey John, I’m just thinking out loud here…. If you add a thumb hole rather than prying with a screw driver do you think that would help solve the dust collection problem you mentioned? Love your videos!

[@JohnMcGrathManInShed]

It could help, it would be worth experimenting with different hole patterns

[@christopherdekonstrukt444]

What if you need one to cut 45 or any degree bevels?

[@MrHighflyingclive]

You mentioned that the original wide slot is an aid to dust collection. Do you think that drilling a series of 20mm or 25mm holes in the wider section of the new insert would be advantageous?

[@JohnMcGrathManInShed]

It could help

[@jowallace-blaker8202]

Great video John......quick question re the table saw. How accurate do you find the measurements on the face rail? I have a slightly different model and struggle to work out out to get the fence to cut say 100mm by using the fence guide measure.

[@JohnMcGrathManInShed]

I use it as a guide only, I measure from the fence to the blade with a steel ruler if I need to be precise.

[@billferrol4202]

John, what make is the router - I've never seen one where you don't have to tighten the collet? Also I have the same saw, but an earlier generation and the riving knife is removable - I know you bought yours second hand so if you don't have the manual you can download on line or I could send you a copy.

[@JohnMcGrathManInShed]

Hi Bill, it is removable if I pull the bolts out, its not removable with the quick release handle. I just didn't want to go to the trouble of taking the bolts out

[@AlansMovies1]

Great video, what router do you use in your table?

[@JohnMcGrathManInShed]

Its a Sauter router

[@oxymoron-om5xm]

as its only friction fit..... do you have problems with the plate lifting?

[@JohnMcGrathManInShed]

Hasn't been a problem so far

[@scrapple8741]

Will the piece stay in place without the clips like the original piece had. My saw has 2 clips in front like forks and a clip in the back to hold it in

[@JohnMcGrathManInShed]

I have not had any issues so far

[@user-qg6fy4yp8t]

Thanks !! Good video...i will drink glass of whiskey for each 5k new subscribers ( untill i will finish the bottle)😉

[@JohnMcGrathManInShed]

😂 Cheers

[@chriscrilly8807]

Go raibh míle maith agat a Sheán! Sábháilteacht ar dtús.

[@merikatools568]

Can i buy an H for Tickness?