Table Saw Zero Clearance Insert

thingiverse

This is a replacement insert for any table saw, with specific measurements for the Craftsman 152 already setup. Designed in OpenSCAD. This can be used to create a zero clearance insert, or a dado stack insert, or an angled zero clearance insert. This is fully customizable for any table saw that has an oval shaped insert by simply changing the measurements. I usually make these out of wood, but having a file already setup to print is a huge time saver.FeaturesFully customizable size, just enter your measurements in the OpenSCAD file. Optional riving knife. Print it with a low profile plastic knife or disable it and install an aftermarket one like the one from MicroJig. Make an extra wide riving knife for dado stacks.Optional set screws for leveling. Print it a tiny bit shorter than your throat and level it with set screws, or print it proud and sand it down for a perfect fit.Optional magnet hold downs.Optional finger hole for easy removal.Print InstructionsMeasure the length, width, and thickness of your throat and enter it in the file.Raise the saw blade and measure from the inside of the throat on the fence side of the saw to the point of a tooth on the blade. Enter this as KnifeInsetMeasure from the front of the throat to the back of the blade at table height, and add an inch or so. Enter this as KnifeXPos.Enter the size of your magnets.Measure the locations for set screws and magnets to where you want the center of the holes. Row1 is towards the front of the saw. Inset is from the inside of the throat to the center of the holes. For ScrewSize measure the diameter of the screw you intend to use and subtract 1.5mm. They should thread in just fine.Render the file and export the STL. Print the file at 25-30% infill on the lower part, and use the Prusa Height Range Modifier to print the top part at 100% infill. This makes the riving knife much stronger.Lower the saw blade and check the fit. It needs to be snug. Check the hole placements. Use the fence on one side of the blade and a block on the other to hold the insert down. Start the saw and slowly raise the blade to cut through the insert. Stop the saw.Place a straight edge along the blade and make sure the riving knife is in the correct place. If its too far towards the fence it will cause problems cutting. If there is a gap between the straight edge and the riving knife it will not do as well preventing kickback. Reprint as needed.Thread in the set screws and attach the magnets with ca glue or epoxy. I was able to just press the magnets in with a small C clamp. Clean up any burrs left from cutting.Level your new insert.Make some sawdust!Set screws and round magnets are readily available on Amazon. The magnets I used are 3mm thick with a 10mm diameter. The set screws are ¼ diameter and 3/8 long with a hex head