Just got a Bosch table saw and I want to make a zero-clearance insert for it. The insert itself is a little thinner than the usual blanks that are sold. I could make one but this is the saw that has the riving knife so I want to stick with the factory types. Has anyone ever filled the cavity with Bondo and raised the blade through that? If so how did that work?
Thanks.
Most nights are crystal clear, but tonight it’s like he’s stuck between stations.
Learn the specific guidelines for location, spacing, and clearance for optimal safety.
"I have learned so much thanks to the searchable articles on the FHB website. I can confidently say that I expect to be a life-long subscriber." - M.K.
Dig into cutting-edge approaches and decades of proven solutions with total access to our experts and tradespeople.
Start Free Trial NowGet instant access to the latest developments in green building, research, and reports from the field.
Start Free Trial Now
Replies
use a piece of 1/2" lexan and make a whole new one..
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming
WOW!!! What a Ride!
Forget the primal scream, just ROAR!!!
I'm lazy. I have Bondo; I don't have lexan. :-)
Most nights are crystal clear, but tonight it's like he's stuck between stations.
Edited 11/19/2007 12:06 pm ET by JJV
cheap too....
so let us know how the Bondo works out...
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
I prefer the term "thrifty". ha ha....
A google search shows me that my idea is not original nor far-fetched. We'll see how it goes.
Most nights are crystal clear, but tonight it's like he's stuck between stations.
thrifty it is...
Life is not a journey to the grave with the intention of arriving safely in a pretty and well preserved body, but rather to skid in broadside, thoroughly used up, totally worn out, and loudly proclaiming<!----><!----><!---->
WOW!!! What a Ride!Forget the primal scream, just ROAR!!!
without re-inforcing, I think the bondo would flake right away or chip off.
Here is how I would try this -
take a piece of glass at least as big as the insert.
spray it down with wax. or paste wax it.
lay the Bosch insert upside down of the glass plate. Maybe sand the smooth spots to give mechanical bondability first
Mix up some clear epoxy along with a bit of ceramic filler beads
Pour that in the slot.
Let it cure.
If need be, sand the finish top smooth again.
Run the spinning blade up through to get the zero clearance slot
Welcome to the
Taunton University of Knowledge FHB Campus at Breaktime.
where ...
Excellence is its own reward!
Didn't think of epoxy. Worth investigating. Don't know if I have enough in the shop though. I try to not keep too much of it around lest it go bad.
Most nights are crystal clear, but tonight it's like he's stuck between stations.
Use phenolic microballoons, not ceramic or silica filler powder - much, much easier on the blade as it's raised through the insert. Something like West System 407 or 410 would be great. The silica filler cures rock-hard.
did
<!---->Cure Diabetes - Whitefish, Montana, 2007!<!---->
<!---->Donate Online!<!---->
How much thinner is the insert? I make my own zero clearance inserts for my Craftsman TS using 1/4" plywood. Since it isn't really 1/4" thick, the insert is slightly below the saw table until I build it up with 3-4 layers of good old duct tape.
I've been doing this for 4-5 years and it works great. I have inserts for several blades, dado cutters, and even one blade insert with a 45* slot thru it. A couple of my old inserts were getting pretty ratty, so a couple of weeks ago, I made a new batch. I'm good for another 4-5 years. - lol