How to Make a Zero Clearance Insert (For Table Saw)

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In this video I’m going to show you how to make a zero clearance insert for your Dewalt DWE7491 table saw! Even though this is specifically for the DWE7491, it can be used for many other table saws. Especially other DeWalt table saws.

I’ll explain why you need a zero clearance insert (safer, better cuts, better dust collection) and then show you how to make it. I’ll cover cutting out the basic shape, zero clearance insert layout, cutting out the tabs, finger hole and adjustment screws so you can level the insert when done. I’ll also show you the safe way to run the blade through your insert.

Now I can make much safer and cleaner cuts with better dust collection.

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-1/2" Plywood

-Table Saw

-Sander

-Drill

-Jigsaw

-1/2" Wood Screws

-Hacksaw

Cut the 1/2" plywood on the table saw to fit in the throat plate slot snug but not tight.

Remove the hardware from an old factory throat plate and clamp it to your work piece. Now mark out the profile, mounting tabs, adjustment screw location and the finger hole location.

Use a fostner bit to drill about a 3/4" finger hole. Drill part way through on one side and finish the hole on the other side to reduce the risk of tear out.

Use a jigsaw to cut out the radii on the ends and cut around any mounting tabs. Leave about a blades width of extra material to be sanded later to the exact size.

Now, test fit the part in the slot on the saw and note any areas that need to be sanded. Then carefully sand and test fit until you have the perfect fit.

Using the marks you made during layout, drill and countersink holes for the adjustment screws. Be sure the holes are slightly smaller than the threads of the screws you plan to use.

Now screw in the adjustment screws and make sure the heads can sit lower than flush when fully tightened.

Now cut off the excess with a hack saw.

With the table saw unplugged and the blade removed, raise the blade adjustment all the way up. Try to install the the new insert and note any areas of interference. If there is interference, cut clearance using a router or whatever other tool you have or makes the most sense.

Reinstall the blade but leave the riving knife off and attempt to install the insert. If you can not install the insert because it's hitting the blade, put your old insert in and cut a blade relief groove in the slot just deep enough to allow you to install it.

Once are able to install it, clamp a scrap 2x4 over the top of it and then turn your table saw on. Now very slowly raise the blade to the maximum height.

Now, observe the location of the riving knife when the blade is all the way up. Mark out extension lines on your insert to allow the riving knife to clear in the max height position.

Now, very carefully, cut out the area for the riving knife with your jigsaw. If your insert is very thin after cutting the blade relief groove, you should reinforce the ends of the relief groove before doing this. I cut some pieces of wood on my table saw and glued and clamped them in place.

Sand all sides of the insert smooth.

Apply paste wax to protect the insert and also reduce friction.

Install your insert and use your adjustment screws to get the insert just below flush with the table.

Turn the saw on and raise the blade to the max height to make sure there are no clearance issues. Then lower it back to a normal level and cut a thin strip of wood to make sure it works as it should.

Enjoy safer, better cuts with a little less dust!