Thanks to everyone who sent advice about zero clearance inserts and splitters. I just got the Lee Valley Feb. Flyer and see the MicroJig splitter featured on the back cover.
My new zero clearance insert:
I took the factory cast aluminum insert and placed a piece of tape across the saw kerf (which was quite sloppy). I turned it over and filled the cavity on the underside, including the kerf with West Systems epoxy, just poured it in and set it level. After curing it, I returned it to the saw, raised the blade and voila – new insert. It still has the factory leveling screws, the hook at the back, to stop it flipping up. Better than new. If it gets beat up I will just repeat. The addition of the epoxy gives it a nice “weighted” feel.
After having a good look at the MicroJig, I am going to make one of those from some plastic scraps I have on hand. Takes time away from woodworking, but I am a tinkerer and I get as much fun from making this stuff as from making furniture. I don’t do this for a living or I would just buy one.
Keith
Replies
Keith,
That is quite an idea. Just one question, what kind of tape did you use?
F E
I just used normal packing tape, like you use to close cardboard boxes.
Certainly for the perfectionist you could still have other inserts for diferent blades etc, I only have one good blade. I don't know if it makes a lot of diference if you cut the slot for full blade height and then use it at a lower height - (see last comment) but I never thought about that before.PS after you pour the epoxy put the insert down on a flat surface so the weight of the epoxy does not bulge the tape while it cures. I also did not use 100% epoxy, I cheated and added some fine sawdust.
Keith
Edited 2/21/2005 10:07 pm ET by Keith
thanks for the reply, I always thought there was an easy way to to this, but was never smart enough to figure it out.
f E
That's a good idea if you only use one blade at on blade height and 90d to the table.
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Michael in San Jose
"In all affairs it's a healthy thing now and then to hang a question mark on the things you have long taken for granted." Bertrand Russell
keith used epoxy to restore his zero clearance insert.
The same effect can be accomplished a tad quicker with Automotive body filler.
Eric in Calgary.
The body fill stuff I use for filling bad holes in timber,I use concrete colour,so as to make it easy when I come to stain up.
What a great idea Keith
That is the best idea I have seen for zero clearance inserts for the factory one. I think I will try it in the near future. I thought maybe I could get a way with the original one, but the wood "frays" easy. Besides, putting a new wood insert would not be able to hold the leveling srews.
Americans drive on parkways and park on driveways
Sweet.
Better shoot this one over to FWW for it's tips section. You might get the prize.
I know I'll be doing this soon as I get my hands on some epoxy.
Thanks Bill, i'll give it a try.
Keith
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