Thread: Table insert not flat

Originally Posted by Giordannetto

I don't intend to give up on the maker's insert. The configuration of this saw, in particular the lack of handwheel adjustment for the bevel angle, appear to make ZCIs problematic for bevel cutting...............

I agree on not giving up on the makers insert. I use my DW745 with the standard insert when ripping, it allows the sawdust to clear easier. I have a ZCI for 90 degree and another for 45 degree. When you make you ZCI make a few, it's easier to make a few at once then you have spares should you need them.

Bosch this morning got back to me and are sending a new, hopefully flat, insert.

Meanwhile in among other things I've cut the polycarbonate tops for three ZCIs and roughly shaped a scrap piece of 19mm jarrah for the underside of the first one. I'm planning to rout a 6 or 8mm wide by 15mm deep trench in the underside of the jarrah before installing the insert and cranking the saw blade up through it. Reasons:
1) the zero clearance part of the insert will only be a few mm thick which seems as if it will help with airflow and sawdust;
2) the standard blade in its lowest position is only a few mm below the table, so if I don't cut this trench I'll have to install a smaller blade to start the slit, and I don't have one with the right spindle diameter and kerf width.

If this insert works out OK I'll make two more, one with the trench widened and angle to suit a bevel cut, the other as a spare.

Just to finish this off: the new insert arrived from Bosch and is dead flat.

And I've made a ZCI, all but the final fitting and re-installing the riving knife. But it's not a good saw for ZCIs: the cast alloy table is only a few millimetres thick. The blade in its lowest position is only 6mm below the surface, and the saw carrier and riving knife attachments at their highest are about the same, so it was a lot of work to fabricate and carve the ZCI to fit the space. So I think I'll keep it for special occasions only.

Thanks to all for the support and suggestions.

John

Good outcome
if you can't readily make a ZCI then try using a sheet of thin ply or mdf and slide it through the blade so as to get a ZCI effect
Rob