Swapped to a zero-clearance insert on my table saw last week

I used to just run dado stacks with the stock throat plate, which left a huge gap around the blade. Last Wednesday I finally cut a zero-clearance insert from some 1/4 inch birch ply I had lying around. The difference in tear-out on plywood edges is night and day, especially on crosscuts. Has anyone else made the switch and noticed less chipping on melamine?

3 comments

3 Comments

king.robin23d ago

Hold on a second there Adam. A dull blade is a problem no matter what insert you're using, sure. But the zero-clearance insert actually helps with melamine too, because it supports the material right up to the cut line. I've run plenty of melamine through mine and it makes a real difference in chipping, especially on the top face. A sharp blade with a good top bevel is still key, but the insert stops that little bit of tear-out you get from the blade lifting the fibers.

the_sam20d agoMost Upvoted

I feel you on this one. I've had that exact same moment where you finally dial in the perfect blade and insert setup and the cut comes out like glass, it's almost magical. Nothing worse than spending all that time dialing in your saw only to have a cheap zero clearance insert let you down when you need it most. Honestly I think most people don't realize how much that little piece of plastic or wood actually does until they've tried it both ways. It's one of those things that seems minor but makes a huge difference in the final product.

adamthompson23d ago

Zero-clearance insert" reminds me of the time I tried cutting melamine with a dull blade...