Replaceable Zero Clearance Insert Base for Ryobi Miter Saw

thingiverse

This is an insert for the Ryobi 10" sliding compound miter saw model TSS102L. This is **not** actually the zero clearance insert itself - this is a base that *holds* an easily-replaceable ~1/4" thick insert of size 1" W x 14-1/8" L x 5.16mm T. I'd say look at the photos for details, but a 500kb photo size limit doesn't exactly get you quality photos. That sucks. There is a recession in this base that is exactly the thickness of the 1/4" plywood that I have lying around the garage. Now I can make zero clearance insert pieces out of wood very easily from strips of ply, without having to shape them to fit the saw and counterbore screw holes in the right places. I recommend making your strips a tight fit on the width of the insert slot, so that they don't pop up out (my one test piece has a curve and wants to lift the ends out of the slot). I drew this as one part then split it across the middle pair of mounting screws, so that it fits on my 220x220 print bed and each half has three of the six mounting screws. I overlapped the pieces a little bit at the split so that they work to hold each other down. The gap in CAD between the faces at the split is 0.2mm, which comes out to be a nice fit on my printer. I added fillets to all external corners to avoid issues with print head inertia, and chamfers to the bottom face edges to counter elephant's foot / first layer squish and to more easily remove the brim that I use with my glass bed. The bottom of the slot is 1.98mm thick, and seems to be sturdy enough. If you need to increase the depth of the slot to hold thicker insert wood... there's probably a limit. Increasing the depth from the current 5.16mm to a true 1/4" (6.35mm) would leave you with less than 1mm of material, since the whole thing is 7.14mm thick overall. Maybe that's enough, maybe it isn't and you'd have to figure something out. I wanted to have the bottom of the slot thicker to begin with, but then you'd need to print this with supports (since you can't modify the height from the mounting faces to the cutting surface) or turn into into a multi-piece assembly where you glue a thin support strip on the underside without interfering with the mounting surfaces. The latter option is probably the way to go.