Zero Clearance Insert from a Chopping Board for a DeWalt DW745 Table Saw
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- Опубликовано: 1 апр 2017
- In this video I make new zero clearance insert for my DeWalt DW745 table saw.
The insert is made using a polyethylene chopping board. 
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I know it's an old video but a tip for future viewers: an easier way to cut the initial kerf when the blade hits the bottom of the insert (throat plate), install the original insert with the fence alongside it. Using dbl stick tape, attach the new insert directly above it. Apply a 2× brace over the right side of the insert & clamp it to the fence to secure it in place. Turn on saw & slowly raise blade all the way up to cut the kerf in the new insert. Remove the old insert & complete the cut up through the new one. It's precise as long as you've lined it up accurately and clamped it down securely. Hope this helps...
I think this is the best solution I've seen to date. Thanks for posting.
This is awesome. Love the lip. Best one I've seen for the dw745. 👍🏻 I need to make a new one but I keep putting it off!
Thanks Keith really appreciate your comments.
The chopping board was really easy to work with; the finish from the router was really good and it cuts like a dream. I'm going to make more stuff from this material I think!
Thanks for showing us how you did that. I just purchased a Dewalt saw last night so I’ll be trying the same thing on the weekend. Thanks again. Much appreciated. 🇦🇺👍🏻
Nicely explained and I love the chopping board idea. One thing- I know others have said about using a pushstick but it can't be said enough. I had a kickback recently with a bit of plywood and looking at the trajectory of the blade marks on the wood, if I hadn't been using a pushstick I'd would have to give up the guitar:-)
I think I just found my new inserts! I've tried a few others and they fall short in in one manner or another. Never thought of the levelling screws. Sure eliminates a lot of shimming and cussing! Lol Thanks!
Great idea that I wish I had seen earlier! I have a similar saw and ended up paying to get a zero clearance insert 3D printed, and still had to file and sand it to get it to fit, when I could have just done what you did and gotten a dollar store cutting board and been off to the races. Nice job!
awesome work. Have only just unpacked my dw745 so this is one for the future!
Thanks Phil.
That is a nice job! I'll copy your work exactly, if I may... I have the same saw and your solution seems the best I've come across. Definite thumbs up!
Thanks Alasdair copy away!
An amazing bit of engineering here! And it's 'on brand' with the colouring too!
Thanks I couldn't have had it any other colour!
Dear Mr HWHL...I loved it...top job and thanks for the great idea...I have the same table saw and will now do the same...cheers.
The cutting board is a great idea! I'll be making TWO of these - one for straight cuts and another for the dado set I want to get.
I can’t claim it was my idea but I thought I’d make a video of it!
Very well done. Very impressed.
very good job. I have a dewalt dw 745 for few months and all your videos on it gave me a lot of ideas. thanks and greetings from France. I like your videos
Bonjour Gilles Merci pour vos commentaires.
Just watched your zero clearance table saw incert and considering you were short changed by Amazon (incorrect dimensions)you worked it out quite well,you overcame the problems you were faced with and made a very good incert which I'm sure that you are pleased with,so I give you my 5 ☆ rating
Nice solution! And nicely implemented. All the best, Rob
Love your vids man. I could watch and listen to you all day 😎
Thanks John.
I never would have thought of this! Good job! 👍🏽
Thanks Britt.
Did a cracking job with the lip and emulating the screws. Great job mate.
Great video and process. Keep up the good work. Thanks for sharing...
Thanks you’re welcome.
I really enjoy watching all of your videos and as I have recently bought the DW745 I am inspired by your video and will be looking to make an zero clearance insert soon. Nice one, keep up the good work on your videos!!!
Thanks Ravi glad you found it useful.
Thanks! Great idea with the cutting board - made this for DADO on my older Ridgid model 4510. Perfect, thanks to you. (The dado insert for my saw is virtually unavailable anymore, and if it were, it would likely be 40USD -- so Double GOOD ON YA, Mate!)
I am glad you knew where the blade was coming up! I cringed until I saw it come clear. LOL.
I just got a DW745 for myself and am planning to make my zero today. Our insert plates are a little different, but I'm glad I saw this because I did not plan for the high section on the side.
I didn't see your riving knife, so I guess you don't use it. On my previous saw, the riving knife has prevented several kickbacks, so I am going to accommodate it.
Instead of routing the track for the blade, I am going to use my stock plate and push my new plate into the blade set just high enough to penetrate the top, and just far enough to reach the end. Then, I can raise the blade through the front of the plate and keep my riving knife attached. I will still have a zero clearance but it will extend past the riving knife.
I noticed that your stock plate did not have a finger hole and you added one. Mine came with one right where you drilled yours. My new one will have one there as well.
I also like the way you did your tabs, well your one big tab, lol. My new plate will be wood, but I may also make the same tab you made.
Thank you for your video.
I'm afraid my DeWalt was short lived. Mine was defective and the fence teeth started curling over within two weeks. It had a few other issues I would have overlooked, but because of the fence, mostly, I returned it to exchange for a new one. Instead of getting another DeWalt, I added a few dollars and stepped up to a more expensive Hitachi c10RJ.
I still love the DeWalts. I just think I got a rare lemon.
Parabéns pelo excelente zero clearence👏👏👏
Tenho um feito com madeira, mas este seu é sensacional, vou tentar fazer igual 🤝
That worked really well. Nice job 👍
Thanks DCPorter71. 👍🏼
Nice job. Well explained and creative use of a poly cutting board. I've got a similar cutting board--white not yellow-- and may be able to duplicate your excellent ideas. Thanks.
Great job man, like it grew there 👍
Well done. Thanks for the contribution. Wish I had watched this before trying the same thing a few hours ago with the same material for the DWE7491.
I did use the routing method as I wanted an exact copy. I did notice the thinner side would move inward with pressure so just screwed it down to keep it in place on the router table.
I didn't want to remove the insert screws from the original and chance messing the height around. So just blacked marked the tips and pressed the original down on the new. Leaving black marked holes. Then centre punch.
To allow for the riving knife. I used my drop saw to lengthen the blade slot to 2mm from the end. Turned over and dropped again. And used the Jigsaw to finish.
For some reason my table saw rising cut was really tight. The drop saw helped to widen enough for a smooth rise and fall.
HTH
Thanks WhoDatBe Dare it's never as easy as you first think!
Happy Wife Happy Life LOL. So true. You make it look so easy.
I think I got lucky with the approach on this one!
Well done mate! Ingenious using a poly cutting board, I never thought of that. Cheers.
Thanks Kevin.
Nice job man. I'll have to make one of those.
You have don a great job with that cutting board well don and thanks for making the video .I recently bought the same saw and yes the gap is to wide now I know how to rectify it .But I love the saw .
Yes,it was a pleasant vidio,I'm sure it will useful to someone who wants to make a zero clearance incert well worthy of my thumbs up
Thanks Colin
outstanding! nice work i believe i will do mine in the same manner! thank you!
This is a really great project. I would suggest, though, that you cut the insert in such a way as to allow your riving knife to come through it, too. It is one of the most important safety pieces that comes with the saw and is very reliable for preventing about 90% of kickbacks.
Very well done, thanks for the inspiration.
Thanks emadigan523. 👍🏼
Great idea and a well made video. I just got rid of my old saw and bought a DeWalt DW745, I do a lot of small cuts and your idea is perfect for my needs. Subscribing.
Cheers for the video mate. I have the same saw. Will be giving this a go.
You’re welcome.
great video. I have the same TS and I absolutely HATE the insert that comes with it. (and don't get me started on the mitre gage). Thanks for sharing this. I will be making one this evening. but please please please use a push-stick. liking and subscribing. keep 'em coming
I like that idea 💡 going to try it!
An innovative woodworker like you is not deserved to gets a thumbs down. It looked like the original Dewalt replacement part!! good job man. Thanks for sharing that with us
Great idea to use a chopping board and it turns out it was better it was thinner than expected
Thanks Andrew
I've heard of guys mounting a circ. saw blade to make the initial slot cut. I have one of these saws and I'll follow your path on this one. Nice work.
Thanks the arbour on my circular saw is a different diameter to the table saw. Blade kerf is thinner too so not an option unfortunately.
Excellent. Now you just need to make one for your dado blade. Great idea using the cutting board.
Don’t have a dado they are not available in the uk. Illegal due to safety reasons. 🤷🏼♂️
@@WheresMyPencilUK Why in the world not? Are they afraid you might "cut" yourself? LOL. Like a table saw isn't dangerous with just a regular blade? I can't believe that!
Yep I think it’s an EU thing now we have left the EU we might be able to buy them soon. 🤞🏼
@@WheresMyPencilUK
Can't you order one online and have it delivered to circumvent that rule?
@@envisionCamusa Table saw models manufactured for use in the EU and here in the UK have a shorter arbor to prevent the use of dado blades! Madness.
Very nice work; however, you're a very brave dude putting your fingers that close to the blade at the end of the video.
Hi there, been following quite a few of your other videos, love them. I have a similar model Dewalt table saw ( the cordless model) and I need a zero clearence insert just like yours. So have a lovely chopping board on its way and will attempt to copy your design, though probably knowing my ham fisted technique, may need to make two :). Keep up the great work mate
Parabéns pelo projeto , vou tentar fazer também foi uma ótima idéia.
Great this, gonna make my own when I get my dewalt table saw, may use a different colour just so i can see what plate I have in at a glance. Gonna put that riving knife in though 😂
Chopping board is a superb idea 👍🏻
Looks great. I had the same problem on my saw of the blade being higher than the supports. I fitted the smaller glad from my circular saw to start the cut.
Badger Workshop good idea I tried the one off my circular saw but the shaft on the table saw is too big for the blade.
Great idea mate
Sweet, nicely done.
Thanks
When i made mine I just put duct tape on the tabs to raise the insert , also to cut the slot . I put a 7 1/4" blade on the raised into the insert,, this is the only insert I don't use the Riving Knife on but I use extra caution when cutting stock --- another use for the extra cutting board make push sticks
First love the idea of using a cutting board. Thinking you could have cut the board in 1/2, glued one on top the other then planed or resawed back down to 1/2 inch. My first attempt at this I used oak which was a very poor choice and cut the slot “almost” long enough for the riving knife. The riving knife at full hieght broke the insert. I am going to try your method next. DeWalt made this typical shop task, 0 clearance insert, a woodworkers challenge for sure.
Nice work.
Very well done.
if you're not using a riving knife, at least use a push stick! But you can add a splitter for a bit more safety.
Nice job mate
Well done!
Great work again!!
Thanks Jon.
Great job , old poly chopping boards may be good for little router jig attachments.
Thanks Michael.
Well thanks for sharing your video. I'm inspired by what you did and will attempt to do the same.
Appreciated.
A Thumbs up from me and a great idea using a chopping board for it, maybe you should make 1 or 2 more as spares.
I use a chopping board to do the runners on my table saw for sleds etc. Well Done.
Barry (ENG)
Thanks Barry I'll probably make another and can use the new one as an accurate template!
Great detail on the video... a suggestion on the raising blade. Start with a 7 1/4 circular saw blade. Simple and quick
Thanks Tim I probably should have said in the video that I tried the blade from my circular saw but it doesn't fit the shaft on my table saw so this was the only option I had.
Interesting... usually tablesaw and circular saw are both 5/8"
Nice job 👍
Thanks for this! I just got a new dewalt dwe7480 and after adjusting and aligning everything, I’m making zero clearance inserts.
You’re welcome.
Nice job mate ,its look realy good.
Thanks Andrzej.
I appreciate ur advice.thank you
Nice job
I had the same problems with my flexvolt table saw. I like a challenge 😂
Nice insert. May I suggest using set (grub) screws instead of regular "headed" screws so that a countersink will not be necessary. Also, to cut the blade slot in my insert I just carefully dropped the insert down onto the spinning blade set to it's lowest position then raised the blade through the insert. Worked great. Lastly, since you're not using any locking mechanism on the front of the insert, the tab in the back is not strictly necessary. The insert on my saw stays in place on it's own.
Thanks, I didn’t want to fork out for grub screws and your a brave man dropping something on a spinning blade. The tab at the back is to stop the rear lifting when stock is placed on the front it was happening with my first version so you are lucky yours is staying put.
Very nice I think I will tray it on my table saw ..
Thanks Paul it makes a difference.
Thanks for the video. Have you done a Mark II version? The insert was the wrong colour - so it's going to (obviously) be better all round! In use do you need a slot for the riving knife? Do you need to hold it down at the other end? Did you really use the bolts from the original insert (now modified, will they still work on the old one)? My first DW745 had the lugs snap on first use. After one year, the same thing has happened again - covered by the warranty again.
Clever thinking good job man 🔨🔨
Thanks.
it was a decent vidio,easy to follow
Cheers Colin.
Just got done making one out of plywood for my old Delta saw. Wanted a plastic one. Could not find any plastic at the hardware stores or lumber yards. Never though to look in the kitchen isle at the local market.
another great video mate. Keep going.
Thanks Martin.
Good, but where is the riving knife fitted ?
When you plunged the 1st cut, did the block of wood help? Ive seen painters tape used but i also though of the wood block above the cut. Let me know pls
it looks pretty good but does the insert flex any?? if it flexes it you could get an angled cut instead of a 90 degree cut. i would also recommend u use some push blocks...
Thanks, perfect idea.
I had thought of using the same kind of material to make a zero clearance insert but I will be adding a glue on type rathe blade and I am not sure what I could use to glue it into place. I want the rathe blade to be custom fit for each zero clearance insert. also, you could loose a finger the way you using the table saw, you absolutely can not cross cut on a table saw with out at least using a table sled or miter gauge,
you could also cut it without the lugs and add then later by inserting and gluing small pieces of flat metal into the chopping board material
Good job, your video is very helpful. Thanks
Thanks for an inspiration. Still I hava a question. Could you make 3 inserts from that board?
I have made several throat plates for several different saws. With that knowledge and experience, I'd like to offer a few suggestions. First, and most importantly, you didn't make the blade slot long enough to accommodate a riving knife, a giant error. Second, an easy way to cut the exact width of the throat plate is to simply put the original throat plate between the fence and the blade and cut. It should be right every time. Third, instead of going to the trouble of drilling holes and putting in leveling screws, simply put a few pieces of good tape on the leveling platforms. You'll get a much cleaner look without those four screws. I saved the best for last. Your idea about cutting a ledge to fit under the table was inspired Bravo!
Oh, one more thing. How did you ever think of using a cutting board on a table saw? Be well.
Thanks for the suggestions.
Thanks for a great video. I'm going to make one just like yours.
👍 nice job 👍
Good work, but you should use the push stick.
Nice job! but It gave me a fright to see those fingers that close to the blade. Please mate, use a push stick next time. You've got too much going for you. No hate, just concern mate. I hope mine turns out as well as yours. Thanks and here's my subscribe and thumbs up! p.s. Don't waste your time responding to the haters. There will always be some, no matter how well you do it.
Nice looking design there mate, it's a great idea to use a chopping board but what about the riving knife ?? where is it ??
Hi. A question. I see that the original plate is locked down in place. Why is this as yours implies that there is no need?
Thank You
Nicely done, I'll have to look around and see if the wife has any plastic cutting boards that are due for an upgrade :-). One thought on cutting the blade slot. Rather than routing out a slot to provide clearance, you might try using a 7 1/2" blade from your circular saw. That would allow you to cut the slot for clearance and then put the regular blade back in. Anyway, great job overall.
Thanks Bill unfortunately the arbour on my circular saw is a different size to that of the table saw. The kerf width is thinner too. So I had to do it this way.
Great Idea
This was excellent and on my to do list. The issue I would have is as my chopping board of choice is thicker than needed. Is it sanding how I should thin the board or if Id use planer will it ruin the blades? Or would you saw extra off?
atteljas if you have the same model saw with the levelling lugs, you could recess the lugs into the insert. Create little pockets for the lugs to sit in on the undersides? Just a thought.
Sounds thats what I need to do. Maybe just use router little there. Thanks for the advice! This was just what I was after =)
My turn now buddy, great video, but all your videos are very good, quality dude yea thumbs up man
Thanks dan.
going to give this a blast
Hope it works ok Simon.
Great video, great idea..you seem to get nice clean cuts with the jig, router, and table saw...I bought a high density polyethylene board and its melting when I cut. Have to cut it twice and go back and clean it with a razor knife. Whyyyyy?!
You might be running an rpm that’s too fast or not have enough teeth on the blade.
good stuff m8!
Hi. I have similar chopping board, but its about 2cm thick. If I would thin it with a planer will planer be dull or ruined?
It would probably work I would take shallow passes though.
Nice job, I've got the makita mlt100 table saw and the inserts less than half that thickness. Makes it a bit trickier to make a decent insert like yours.
Thanks you could try fitting splines or supports to the underside to make it more solid if you are making a thin one.
I've seen people make them with a rebate round the outside to fit into slimmer profiled saws.
Kris Mark Duthie Cheer's, will have look on youtube
Hi, another great idea for the saw many thanks, just one point though. At 10.30 you advise that material on the left side of the saw insert was preventing the snug fit of the plate and that you removed this with your router off camera. Are you talking about the guard mesh around the saw ? It does sit a little above the height of the screw platform on the left hand side but does this need to be removed (with a router !)
Cheers Christopher.
I removed the material on the left underside of the insert with the router just to be sure it wouldn't touch the saw housing and cloth material. It probably would have been ok given the screws raised it by about 2mm. Didn't take long as I was routing out the slot for the blade. 👍🏼
I plan on tapping the holes and use 10mm long grub screws to fine tune the hight when I get about to make my own insert(s).
Henrik Paulsen carry on mate
Same here. I'll also put a couple on each side to make it fit tighter.
Stumpynubs has the best idea I've ever seen. He marks the areas where the screw holes are underneath on the back of the plate. He puts paste wax on the nubs where the plate sets/has the screw holes. Then he quickly puts hot glue on those four places on the back of the plate and sets it in the hole pushing it to flat on plane with the top with a couple straight pieces. The glue hardens and it fits perfectly flat with the table top.
@rats arsed I haven't had the time to make one like that myself yet. So I don't know from my own experience. Stumpynubs has a professional shop and it's what he does so I'm guessing it works well for the long haul. You can find the video on his channel and see exactly how he does it.
In my experience hot glue doesn’t stick well to HDPE which is what the chopping boards are made of.