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I've had a zero clearance insert sitting around my shop forever (a few years anyway) that I never go installed into my table saw. While working on the raised drawer fronts it became quickly apparent that I was going to have to do SOMETHING to keep the short end of the small drawers from falling into the blade opening of my standard insert while they were being cut, so I finally bit the bullet and figured out how to get the inset put in:

Of course now I'm kicking myself for not doing this earlier (like when I was doing the simple kitchen cabinet). I'm going to have to find a couple more of these so I can make one for my Dado Set.

The drawer fronts are coming along. I'm doing them in sets of three.... the first night I put the 1st coat on one set of three. Last night I put a first coat on the 2nd set of 3 and the 2nd coat on the first set of three.

One coat:

Two Coats:

The built in face frame got 3 coats, so I have one more to go on the first set of three. Here is a "naked" board next to one with 2 coats:

So tonight, the 3rd set will get the 1st coat, the 2nd set will get the 2nd coat and the 1st set will get the 3rd right? Thankfully there are only 4 sets of 3 drawers each.

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Comment by Alfred Langen on April 1, 2010 at 10:06am
Right on. One of the first things I did for myself is create an insert from a very nice quality piece of plywood scrap (I throw nothing away.) It took a bit of doing because I did not have a planer at the time. I now have two of these for making dado cuts.
Comment by Kerry Drake on February 24, 2010 at 12:10pm
Mine was a gift. I did not make it. I would be afraid of using plexiglass. I have seen people make them out of wood (a nice quality piece of plywood of the right thickness). Take your existing insert out and just measure how thick it is.

One thing to note is that commercial inserts (like mine) have 4 set screws in them so you can get them dead even with the table top.
Comment by wallace freeman on February 24, 2010 at 11:41am
did you make the insert, or buy it from a dealer? If you make it how do you get it to the right thickness? Do you think 1/8 plexoglass will work?
Comment by Jenny on February 1, 2010 at 2:48am
"I don't know"
Comment by Gary K. Oldham on January 31, 2010 at 8:23pm
No, What's on first, Who's on second! Is that right??????
Comment by Steve Gronsky on January 28, 2010 at 10:24pm

You seem to have the math down correctly. For a moment I thought there was gonna be a question like "Who's on First?"

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