Zero Clearance Insert from a Chopping Board for a DeWalt DW745 Table Saw

In this video I make new zero clearance insert for my DeWalt DW745 table saw.
The insert is made using a polyethylene chopping board.

[@colleenstone6491]

I know it's an old video but a tip for future viewers: an easier way to cut the initial kerf when the blade hits the bottom of the insert (throat plate), install the original insert with the fence alongside it. Using dbl stick tape, attach the new insert directly above it. Apply a 2× brace over the right side of the insert & clamp it to the fence to secure it in place. Turn on saw & slowly raise blade all the way up to cut the kerf in the new insert. Remove the old insert & complete the cut up through the new one. It's precise as long as you've lined it up accurately and clamped it down securely. Hope this helps...

[@ohadkondor7792]

I think this is the best solution I've seen to date. Thanks for posting.

[@RagnBoneBrown]

This is awesome. Love the lip. Best one I've seen for the dw745. 👍🏻 I need to make a new one but I keep putting it off!

[@WheresMyPencilUK]

Thanks Keith really appreciate your comments. The chopping board was really easy to work with; the finish from the router was really good and it cuts like a dream. I'm going to make more stuff from this material I think!

[@johnwalters5400]

Nicely explained and I love the chopping board idea. One thing- I know others have said about using a pushstick but it can't be said enough. I had a kickback recently with a bit of plywood and looking at the trajectory of the blade marks on the wood, if I hadn't been using a pushstick I'd would have to give up the guitar:-)

[@shedmanx3640]

Thanks for showing us how you did that. I just purchased a Dewalt saw last night so I’ll be trying the same thing on the weekend. Thanks again. Much appreciated. 🇦🇺👍🏻

[@alasdairmackenzie515]

That is a nice job! I'll copy your work exactly, if I may... I have the same saw and your solution seems the best I've come across. Definite thumbs up!

[@WheresMyPencilUK]

Thanks Alasdair copy away!

[@adamcoe]

Great idea that I wish I had seen earlier! I have a similar saw and ended up paying to get a zero clearance insert 3D printed, and still had to file and sand it to get it to fit, when I could have just done what you did and gotten a dollar store cutting board and been off to the races. Nice job!

[@woodprojectswithalex2692]

An innovative woodworker like you is not deserved to gets a thumbs down. It looked like the original Dewalt replacement part!! good job man. Thanks for sharing that with us

[@BennettPictures]

An amazing bit of engineering here! And it's 'on brand' with the colouring too!

[@WheresMyPencilUK]

Thanks I couldn't have had it any other colour!

[@Ravi-or6xc]

I really enjoy watching all of your videos and as I have recently bought the DW745 I am inspired by your video and will be looking to make an zero clearance insert soon. Nice one, keep up the good work on your videos!!!

[@WheresMyPencilUK]

Thanks Ravi glad you found it useful.

[@BlessedLaymanNC]

I am glad you knew where the blade was coming up! I cringed until I saw it come clear. LOL. I just got a DW745 for myself and am planning to make my zero today. Our insert plates are a little different, but I'm glad I saw this because I did not plan for the high section on the side. I didn't see your riving knife, so I guess you don't use it. On my previous saw, the riving knife has prevented several kickbacks, so I am going to accommodate it. Instead of routing the track for the blade, I am going to use my stock plate and push my new plate into the blade set just high enough to penetrate the top, and just far enough to reach the end. Then, I can raise the blade through the front of the plate and keep my riving knife attached. I will still have a zero clearance but it will extend past the riving knife. I noticed that your stock plate did not have a finger hole and you added one. Mine came with one right where you drilled yours. My new one will have one there as well. I also like the way you did your tabs, well your one big tab, lol. My new plate will be wood, but I may also make the same tab you made. Thank you for your video.

[@BlessedLaymanNC]

I'm afraid my DeWalt was short lived. Mine was defective and the fence teeth started curling over within two weeks. It had a few other issues I would have overlooked, but because of the fence, mostly, I returned it to exchange for a new one. Instead of getting another DeWalt, I added a few dollars and stepped up to a more expensive Hitachi c10RJ. I still love the DeWalts. I just think I got a rare lemon.

[@garybarchas4984]

I think I just found my new inserts! I've tried a few others and they fall short in in one manner or another. Never thought of the levelling screws. Sure eliminates a lot of shimming and cussing! Lol Thanks!

[@gillessophie6158]

very good job. I have a dewalt dw 745 for few months and all your videos on it gave me a lot of ideas. thanks and greetings from France. I like your videos

[@WheresMyPencilUK]

Bonjour Gilles Merci pour vos commentaires.

[@hughelgar2540]

if you're not using a riving knife, at least use a push stick! But you can add a splitter for a bit more safety.

[@eileenpickett431]

Just watched your zero clearance table saw incert and considering you were short changed by Amazon (incorrect dimensions)you worked it out quite well,you overcame the problems you were faced with and made a very good incert which I'm sure that you are pleased with,so I give you my 5 ☆ rating

[@TimRoyalPastortim]

Great detail on the video... a suggestion on the raising blade. Start with a 7 1/4 circular saw blade. Simple and quick

[@WheresMyPencilUK]

Thanks Tim I probably should have said in the video that I tried the blade from my circular saw but it doesn't fit the shaft on my table saw so this was the only option I had.

[@TimRoyalPastortim]

Interesting... usually tablesaw and circular saw are both 5/8"

[@larsonbennett5903]

Very nice work; however, you're a very brave dude putting your fingers that close to the blade at the end of the video.

[@barryroberts6470]

A Thumbs up from me and a great idea using a chopping board for it, maybe you should make 1 or 2 more as spares. I use a chopping board to do the runners on my table saw for sleds etc. Well Done. Barry (ENG)

[@WheresMyPencilUK]

Thanks Barry I'll probably make another and can use the new one as an accurate template!

[@Badgerworkshop]

Looks great. I had the same problem on my saw of the blade being higher than the supports. I fitted the smaller glad from my circular saw to start the cut.

[@WheresMyPencilUK]

Badger Workshop good idea I tried the one off my circular saw but the shaft on the table saw is too big for the blade.

[@jammywesty91]

Did a cracking job with the lip and emulating the screws. Great job mate.

[@rayscrafield2106]

Excellent. Now you just need to make one for your dado blade. Great idea using the cutting board.

[@WheresMyPencilUK]

Don’t have a dado they are not available in the uk. Illegal due to safety reasons. 🤷🏼‍♂️

[@rayscrafield2106]

@@WheresMyPencilUK Why in the world not? Are they afraid you might "cut" yourself? LOL. Like a table saw isn't dangerous with just a regular blade? I can't believe that!

[@WheresMyPencilUK]

Yep I think it’s an EU thing now we have left the EU we might be able to buy them soon. 🤞🏼

[@envisionCamusa]

@@WheresMyPencilUK Can't you order one online and have it delivered to circumvent that rule?

[@cisforcallan]

@@envisionCamusa Table saw models manufactured for use in the EU and here in the UK have a shorter arbor to prevent the use of dado blades! Madness.

[@tensor131]

awesome work. Have only just unpacked my dw745 so this is one for the future!

[@WheresMyPencilUK]

Thanks Phil.

[@felixreali7101]

great video. I have the same TS and I absolutely HATE the insert that comes with it. (and don't get me started on the mitre gage). Thanks for sharing this. I will be making one this evening. but please please please use a push-stick. liking and subscribing. keep 'em coming

[@whoDatBeDare]

Well done. Thanks for the contribution. Wish I had watched this before trying the same thing a few hours ago with the same material for the DWE7491. I did use the routing method as I wanted an exact copy. I did notice the thinner side would move inward with pressure so just screwed it down to keep it in place on the router table. I didn't want to remove the insert screws from the original and chance messing the height around. So just blacked marked the tips and pressed the original down on the new. Leaving black marked holes. Then centre punch. To allow for the riving knife. I used my drop saw to lengthen the blade slot to 2mm from the end. Turned over and dropped again. And used the Jigsaw to finish. For some reason my table saw rising cut was really tight. The drop saw helped to widen enough for a smooth rise and fall. HTH

[@WheresMyPencilUK]

Thanks WhoDatBe Dare it's never as easy as you first think!

[@whoDatBeDare]

Happy Wife Happy Life LOL. So true. You make it look so easy.

[@WheresMyPencilUK]

I think I got lucky with the approach on this one!

[@michaelevans1658]

Great job , old poly chopping boards may be good for little router jig attachments.

[@WheresMyPencilUK]

Thanks Michael.

[@darkdelta]

I've heard of guys mounting a circ. saw blade to make the initial slot cut. I have one of these saws and I'll follow your path on this one. Nice work.

[@WheresMyPencilUK]

Thanks the arbour on my circular saw is a different diameter to the table saw. Blade kerf is thinner too so not an option unfortunately.

[@robmcmahon6782]

Great this, gonna make my own when I get my dewalt table saw, may use a different colour just so i can see what plate I have in at a glance. Gonna put that riving knife in though 😂 Chopping board is a superb idea 👍🏻

[@lincolndickerson1293]

First love the idea of using a cutting board. Thinking you could have cut the board in 1/2, glued one on top the other then planed or resawed back down to 1/2 inch. My first attempt at this I used oak which was a very poor choice and cut the slot “almost” long enough for the riving knife. The riving knife at full hieght broke the insert. I am going to try your method next. DeWalt made this typical shop task, 0 clearance insert, a woodworkers challenge for sure.

[@Bill_CBR]

Nicely done, I'll have to look around and see if the wife has any plastic cutting boards that are due for an upgrade :-). One thought on cutting the blade slot. Rather than routing out a slot to provide clearance, you might try using a 7 1/2" blade from your circular saw. That would allow you to cut the slot for clearance and then put the regular blade back in. Anyway, great job overall.

[@WheresMyPencilUK]

Thanks Bill unfortunately the arbour on my circular saw is a different size to that of the table saw. The kerf width is thinner too. So I had to do it this way.

[@Blfisher82]

I never would have thought of this! Good job! 👍🏽

[@WheresMyPencilUK]

Thanks Britt.

[@DCPorter71]

That worked really well. Nice job 👍

[@WheresMyPencilUK]

Thanks DCPorter71. 👍🏼

[@williamstubbs9737]

Nice job! but It gave me a fright to see those fingers that close to the blade. Please mate, use a push stick next time. You've got too much going for you. No hate, just concern mate. I hope mine turns out as well as yours. Thanks and here's my subscribe and thumbs up! p.s. Don't waste your time responding to the haters. There will always be some, no matter how well you do it.

[@adencitydiy73]

Good work, but you should use the push stick.

[@LogicalUnitZero]

The cutting board is a great idea! I'll be making TWO of these - one for straight cuts and another for the dado set I want to get.

[@WheresMyPencilUK]

I can’t claim it was my idea but I thought I’d make a video of it!

[@KRColson]

Well done mate! Ingenious using a poly cutting board, I never thought of that. Cheers.

[@WheresMyPencilUK]

Thanks Kevin.

[@galland3496]

Good, but where is the riving knife fitted ?

[@JF-mq8tp]

I have made several throat plates for several different saws. With that knowledge and experience, I'd like to offer a few suggestions. First, and most importantly, you didn't make the blade slot long enough to accommodate a riving knife, a giant error. Second, an easy way to cut the exact width of the throat plate is to simply put the original throat plate between the fence and the blade and cut. It should be right every time. Third, instead of going to the trouble of drilling holes and putting in leveling screws, simply put a few pieces of good tape on the leveling platforms. You'll get a much cleaner look without those four screws. I saved the best for last. Your idea about cutting a ledge to fit under the table was inspired Bravo! Oh, one more thing. How did you ever think of using a cutting board on a table saw? Be well.

[@WheresMyPencilUK]

Thanks for the suggestions.

[@AerialLensVideo]

Thanks! Great idea with the cutting board - made this for DADO on my older Ridgid model 4510. Perfect, thanks to you. (The dado insert for my saw is virtually unavailable anymore, and if it were, it would likely be 40USD -- so Double GOOD ON YA, Mate!)

[@planbcool4318]

Nice job, I've got the makita mlt100 table saw and the inserts less than half that thickness. Makes it a bit trickier to make a decent insert like yours.

[@WheresMyPencilUK]

Thanks you could try fitting splines or supports to the underside to make it more solid if you are making a thin one.

[@krismarkduthie2178]

I've seen people make them with a rebate round the outside to fit into slimmer profiled saws.

[@planbcool4318]

Kris Mark Duthie Cheer's, will have look on youtube

[@Dewelful]

Love your vids man. I could watch and listen to you all day 😎

[@WheresMyPencilUK]

Thanks John.

[@petermarshall4733]

You have don a great job with that cutting board well don and thanks for making the video .I recently bought the same saw and yes the gap is to wide now I know how to rectify it .But I love the saw .

[@thomasgreen8532]

I had thought of using the same kind of material to make a zero clearance insert but I will be adding a glue on type rathe blade and I am not sure what I could use to glue it into place. I want the rathe blade to be custom fit for each zero clearance insert. also, you could loose a finger the way you using the table saw, you absolutely can not cross cut on a table saw with out at least using a table sled or miter gauge,

[@grahamlumsden8471]

Very well done. Very impressed.

[@MrCOUNTYCORK]

Great job man, like it grew there 👍

[@emadigan523]

Very well done, thanks for the inspiration.

[@WheresMyPencilUK]

Thanks emadigan523. 👍🏼

[@DeanHoyt79]

Great idea and a well made video. I just got rid of my old saw and bought a DeWalt DW745, I do a lot of small cuts and your idea is perfect for my needs. Subscribing.

[@jeanlouisroederer5140]

Nice job. Well explained and creative use of a poly cutting board. I've got a similar cutting board--white not yellow-- and may be able to duplicate your excellent ideas. Thanks.

[@Waltkat]

Nice insert. May I suggest using set (grub) screws instead of regular "headed" screws so that a countersink will not be necessary. Also, to cut the blade slot in my insert I just carefully dropped the insert down onto the spinning blade set to it's lowest position then raised the blade through the insert. Worked great. Lastly, since you're not using any locking mechanism on the front of the insert, the tab in the back is not strictly necessary. The insert on my saw stays in place on it's own.

[@WheresMyPencilUK]

Thanks, I didn’t want to fork out for grub screws and your a brave man dropping something on a spinning blade. The tab at the back is to stop the rear lifting when stock is placed on the front it was happening with my first version so you are lucky yours is staying put.

[@AndrewMcQuillen]

Great idea to use a chopping board and it turns out it was better it was thinner than expected

[@WheresMyPencilUK]

Thanks Andrew

[@RobWhittlestone]

Nice solution! And nicely implemented. All the best, Rob

[@DGFX64]

Dear Mr HWHL...I loved it...top job and thanks for the great idea...I have the same table saw and will now do the same...cheers.

[@smattext]

outstanding! nice work i believe i will do mine in the same manner! thank you!

[@BlessedLaymanNC]

This is a really great project. I would suggest, though, that you cut the insert in such a way as to allow your riving knife to come through it, too. It is one of the most important safety pieces that comes with the saw and is very reliable for preventing about 90% of kickbacks.

[@JamesDK9]

you could also cut it without the lugs and add then later by inserting and gluing small pieces of flat metal into the chopping board material

[@Glenfiddich101]

Nice looking design there mate, it's a great idea to use a chopping board but what about the riving knife ?? where is it ??

[@wayneg2139]

Just got done making one out of plywood for my old Delta saw. Wanted a plastic one. Could not find any plastic at the hardware stores or lumber yards. Never though to look in the kitchen isle at the local market.

[@colinaskey9777]

Yes,it was a pleasant vidio,I'm sure it will useful to someone who wants to make a zero clearance incert well worthy of my thumbs up

[@WheresMyPencilUK]

Thanks Colin

[@MartinMosman]

Nice job man. I'll have to make one of those.

[@cheesegrater2018]

Nice work man! Now make another spare as well as a few for different angles :D

[@WheresMyPencilUK]

Cheesegrater I will make another at some point. Can use this one as a template for my router. 👍🏼

[@cdodsworth]

Hi there, been following quite a few of your other videos, love them. I have a similar model Dewalt table saw ( the cordless model) and I need a zero clearence insert just like yours. So have a lovely chopping board on its way and will attempt to copy your design, though probably knowing my ham fisted technique, may need to make two :). Keep up the great work mate

[@emrecenkers9721]

Hello , I put some hot silicone drops to leveling platforms till I get the Zero Clearance flush with surface and it works extremely well.

[@danny26barrow]

My turn now buddy, great video, but all your videos are very good, quality dude yea thumbs up man

[@WheresMyPencilUK]

Thanks dan.

[@thefakemaker]

Cheers for the video mate. I have the same saw. Will be giving this a go.

[@WheresMyPencilUK]

You’re welcome.

[@eustacehyliger3487]

Well thanks for sharing your video. I'm inspired by what you did and will attempt to do the same. Appreciated.

[@HepauDK]

I plan on tapping the holes and use 10mm long grub screws to fine tune the hight when I get about to make my own insert(s).

[@DoNnEgRoW]

Henrik Paulsen carry on mate

[@tommgunn4219]

Same here. I'll also put a couple on each side to make it fit tighter.

[@yepper1165]

Stumpynubs has the best idea I've ever seen. He marks the areas where the screw holes are underneath on the back of the plate. He puts paste wax on the nubs where the plate sets/has the screw holes. Then he quickly puts hot glue on those four places on the back of the plate and sets it in the hole pushing it to flat on plane with the top with a couple straight pieces. The glue hardens and it fits perfectly flat with the table top.

[@yepper1165]

@rats arsed I haven't had the time to make one like that myself yet. So I don't know from my own experience. Stumpynubs has a professional shop and it's what he does so I'm guessing it works well for the long haul. You can find the video on his channel and see exactly how he does it.

[@WheresMyPencilUK]

In my experience hot glue doesn’t stick well to HDPE which is what the chopping boards are made of.

[@lenmorris9164]

When i made mine I just put duct tape on the tabs to raise the insert , also to cut the slot . I put a 7 1/4" blade on the raised into the insert,, this is the only insert I don't use the Riving Knife on but I use extra caution when cutting stock --- another use for the extra cutting board make push sticks

[@howardwaite4489]

for the adjusting screws I would of used grub screws instead no need to counter sink holes for the screw heads

[@WheresMyPencilUK]

Sometimes you just use what you have in the drawer Howard.

[@ecaff9515]

Great video and process. Keep up the good work. Thanks for sharing...

[@WheresMyPencilUK]

Thanks you’re welcome.

[@isaiasdelamarta8442]

Parabéns pelo excelente zero clearence👏👏👏 Tenho um feito com madeira, mas este seu é sensacional, vou tentar fazer igual 🤝

[@SmokinGun55]

Very well done.

[@X3WorkshopDesigns]

Thanks for this! I just got a new dewalt dwe7480 and after adjusting and aligning everything, I’m making zero clearance inserts.

[@WheresMyPencilUK]

You’re welcome.

[@a.s.projects1082]

Nice job mate ,its look realy good.

[@WheresMyPencilUK]

Thanks Andrzej.

[@SIRRONW]

it looks pretty good but does the insert flex any?? if it flexes it you could get an angled cut instead of a 90 degree cut. i would also recommend u use some push blocks...

[@TheJonkilleen]

Great work again!!

[@WheresMyPencilUK]

Thanks Jon.

[@martinbrace7195]

another great video mate. Keep going.

[@WheresMyPencilUK]

Thanks Martin.

[@colinaskey9777]

it was a decent vidio,easy to follow

[@WheresMyPencilUK]

Cheers Colin.

[@googlesbitch]

Be aware blade can be destroyed when a zero clearance is used and arbor is tilted. I like to use a zero clearance that can be lifted off and reinserted without tools so by default I leave the factory insert on and then use a zero clearance when needed.

[@Captleemo]

Could you have used a 7.5 inch circular saw blade just to get the hole started and then put your 10 inch blade back in? Oh and I really like the idea of using a plastic cutting board for an insert.

[@angelocillo6543]

That's what I thought when I was watching

[@WheresMyPencilUK]

Unfortunately the arbour and kerf on my circular saw are different to my table saw. 🤷🏼‍♂️

[@Coggy-ci7qy]

Hi, another great idea for the saw many thanks, just one point though. At 10.30 you advise that material on the left side of the saw insert was preventing the snug fit of the plate and that you removed this with your router off camera. Are you talking about the guard mesh around the saw ? It does sit a little above the height of the screw platform on the left hand side but does this need to be removed (with a router !)

[@WheresMyPencilUK]

Cheers Christopher. I removed the material on the left underside of the insert with the router just to be sure it wouldn't touch the saw housing and cloth material. It probably would have been ok given the screws raised it by about 2mm. Didn't take long as I was routing out the slot for the blade. 👍🏼

[@daleriff]

I like that idea 💡 going to try it!

[@markjarman7819]

I had the same problems with my flexvolt table saw. I like a challenge 😂

[@stuartwhelan3258]

Nice job mate

[@huejanus5505]

Mdf scraps are a lot cheaper. Couple of layers of aluminum tape and it's perfect. Ps. Use a router table, not a hand held router. Edit: You can also put aluminum tape on the insert before copying it for an absolutely gap free fit.

[@MrChewy63]

Great idea mate

[@brocherboy08]

Sweet, nicely done.

[@WheresMyPencilUK]

Thanks

[@hiseminencetheholymacdiarmada]

Well done!

[@adjenkinsuk]

I'm sorry but it has to be said. The insert, although functionally sound is not quite the right shade of "Dewalt" yellow 😉

[@WheresMyPencilUK]

And it irritates me every single day! 😜

[@FIREBALL5307]

Very nice I think I will tray it on my table saw ..

[@WheresMyPencilUK]

Thanks Paul it makes a difference.

[@316woodworks9]

When you plunged the 1st cut, did the block of wood help? Ive seen painters tape used but i also though of the wood block above the cut. Let me know pls

[@Khuneidi]

You could use a thicker plywood board like 18mm but route the edges thinner where the adjustment screws sets where you could add them for adjustment Had the same issue and when using 18mm plywood it feels more robust and steady

[@starpaulo747]

Parabéns pelo projeto , vou tentar fazer também foi uma ótima idéia.

[@johnnyt7965]

Nice work.

[@elvisoshaughnessy1255]

I appreciate ur advice.thank you

[@ios6605]

Clever thinking good job man 🔨🔨

[@WheresMyPencilUK]

Thanks.

[@howardlaunius7484]

Nice job

[@DTSVK]

Thanks for an inspiration. Still I hava a question. Could you make 3 inserts from that board?

[@donniemacaskill9908]

Hi On the left hand side of the blade (front of saw ) on the throat plate there is a cut out on the plate why do you not need to cut this out on the one that you made ?

[@amorgan5844]

Its where the blade guard is supposed to rest to keep it centered. He doesnt have that or the riving knife attached so no need for the slots.

[@mertothe1st.258]

Nice Zero Clearance...you could extend the slot and mount a splitter?

[@BlessedLaymanNC]

No one else replied, so I will... There are some great videos on adding splitters to inserts. The Wood Whisperer has one where he runs his insert plate through the blade instead of raising the blade through it. Then, he adds a splitter behind the blade so when he raises the blade, it trims the splitter to curve over the blade a little. I believe he said he made several inserts with splitters to cover two different heights of the blade and for different width blades. When I make my zero insert plates, I plan to make one with splitters to cover the blade of 7 1/4 inch blades since the riving knife is so far away from the blade. My DW745 came with a riving knife so I'll be using it. My friend and I will be making zero clearance plates today or tomorrow, and his saw is old and does not have the riving knife so we are making multiple inserts for different heights of the blade and different blades. Using the plastic cutting boards, I am not sure how well you can glue or mount the splitters. I have so make 6 or more of these plates for all the different blades and angles I primarily use, so I'll be using wood to save money. (I have the wood, LOL)

[@dwaynemartin8305]

Nice job 👍

[@JK-zx3go]

Thanks, perfect idea.

[@duczman76]

😂😂 nice channel name.i'm often asking me the same when i build something.that's the curse having attached too much pockets in your clothes.best i should make myself an extra pad where i mark everything and attach the pencil to it with a string..in hope this works