How to make a perfect zero clearance table saw insert a step by step DIY tutorial

How to make a perfect zero clearance insert for a DeWalt jobsite table saw.

The only design advantage of the additional clearance provided on the factory insert (throat plate) is the ability to use the blade at full height in all of it's possible positions from 0 to 45 degrees, all with the same insert. The factory insert is the most versatile design giving the user the ability to make the widest range of possible cuts with only a single insert. The extra clearance provided on the factory throat plate isn't helpful beyond the versatility aspect and at times can be down right dangerous.

A zero clearance insert is an insert made for a single blade angle or operation. The insert is blank and will be cut through with a specific blade and depth for the exact application. The term zero clearance means there is no additional clearance beyond what is needed for the blade (and riving knife if using one).The advantage of a zero clearance insert is improved dust collection and a more precise cutting surface that provides support of the work piece all the way up to the blade. A zero clearance insert is a design for accuracy but must be changed out when changing blade sizes and/or blade tilt positions.

If you are making a zero clearance insert for use with a 10" blade there are a few things to be aware of.
If you are using the riving knife it will have to come off for the cutting through operation and the remaining area for the knife behind where the blade didn't cut through will have to be cut out separately. Also, the blade will not fit under the blank insert even when lowered down to it's lowest point. The blank insert will be resting on the blade and holding the insert up off the table saw. You must hold the front of the insert up enough to clear the blade, turn on the saw, and with the back tabs of the insert locked into place, carefully lower it down onto the spinning blade to make the original cut into the insert. You will carefully lower the insert down into it's resting position in the table top. The blade will not come all the way through during this first step but still be careful to only handle the forward edge area of the insert. Keep downward pressure on the leading edge of the insert and slowly raise the blade up to the desired cut depth.


The other zero clearance insert videos

https://www.youtube.com/watch?v=T4H2t4fNpOg

https://www.youtube.com/watch?v=krvJiaMOxKk&t=90s

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