DeWalt 7491 table saw zero clearance insert end
thingiverse
I needed a custom template for my DW7491 table saw to cut zero-clearance inserts with precision. This straightforward design enables you to accurately cut rounded ends using a flush-trim bit on your router. The template covers the semi-circular edges and 2 cm of the straight section, ensuring a precise fit. You'll need to print two identical copies and place them in the table saw slot with the circular pad facing upwards. Next, apply double-sided tape to the circular pad and attach an insert blank to it securely. Now, use your router to cut around the template carefully, then trim the sides to ensure a snug fit. Finally, add a couple of nails at the end to match the retention nubs on your table saw for secure installation.
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