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  1. #1
    Join Date
    Jan 2009
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    Australia
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    1,220

    Default Harvey sawtable zero clearance insert

    I have the Harvey sawtable HW110HB. I am trying to get a zero clearance insert for it.
    Major tools don't have one. They don't think it was an option for it as an original equipment.
    They are checking for me.
    So in the meantime I thought I'd throw it out to the forum gurus.
    To make one I got some HDPE and had a go. But stuffed it up.
    What I might try next is a template of the inside and use a flushcut router with a bearing follower.
    Looking at the photos, would I be on the right track??
    Thanks in advance for any suggestions.
    Lyle
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  3. #2
    Join Date
    May 2011
    Location
    Albury
    Posts
    3,019

    Default

    You can use the original insert as a template. Any high density MDF type material of a suitable thickness will do for your zero clearance inserts - I find the MDF, hard surface coated floating floor material works well. Stick the original insert to the ZCI material with double sided tape (masking tape stuck to each surface and then glued together with super glue also works), then use a bearing guided template bit on the router table to accurately cut the shape. You can make any adjustment cuts for the bearing surfaces once you have the completed blank fitting well. When I make these I always make a few, you don't need to be precious about them then. Lower the saw blade, fit the ZCI blank, start the saw and raise the blade through the ZCI.

  4. #3
    Join Date
    Aug 2006
    Location
    Canberra - West Belco
    Age
    63
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    646

    Default

    What aldav said, with one twist, I would make a master copy of your existing plate then use the master to make subsequent copies.

    Depending how well/tight the original plate fitted you can effectively make your master fractional larger by one or more layers masking tape on the side of the original.

  5. #4
    Join Date
    Jun 2018
    Location
    Melbourne
    Posts
    940

    Default

    Look at Hooked on Wood on Youtube.
    He has a Harvey and made his own.
    It may help.

  6. #5
    Join Date
    Jan 2009
    Location
    Adelaide
    Posts
    193

    Default

    That looks identical to the Carbatec TS-C250 throat plates. Same screw arrangement and appears to be the same depth. If it were me I'd be willing to gamble $160 on one of these

    Zero Clearance Insert to suit Carbatec TS-C250P | Carbatec

    The main issue with the Carbatec, Harvey or other similar saws is the depth of the throat plate. Doesnt really provide a lot of options in terms of making your own. You can do it but it needs to be a fairly stiff material.

  7. #6
    Join Date
    Jan 2009
    Location
    Australia
    Posts
    1,220

    Default

    Thanks all.
    The first attempt was 10mm HDPE. I chose that to get rigidity between the support lugs. As you can see in the photo there is a fair space between the front and rear support lugs.

    I'll chase up that suggested video. That Carbarec does look very similar.! I'll have to check it out. Thanks.

    I'm thinking I'll need to make several templates to achieve this. Maybe two, one as a "filler" at level with the lugs, and one for the top, then glue them together.
    Lyle
    Last edited by Lyle; 26th November 2020 at 08:31 AM. Reason: Added text

  8. #7
    Join Date
    Jan 2009
    Location
    Australia
    Posts
    1,220

    Default

    That Carbatec zci really does look like it'll fit.
    Called them but they can't say for certain.
    I've arranged to get one from Sydney next time I'm going there. I'll take my insert to see if it is the same. If it is close I'll bring it back and test it for fit. If not they said l'd be able to return it (without cutting it of course).
    Lyle

  9. #8
    Join Date
    Nov 2007
    Location
    melbourne australia
    Posts
    2,621

    Default

    So do you need an aluminium cutting blade to cut the slot in the Carbatec ZCI?

  10. #9
    Join Date
    Jan 2009
    Location
    Adelaide
    Posts
    193

    Default

    No, any carbide tip blade will do. Just raise the blade slow and steady and be prepared for aluminium shavings to be thrown everywhere.

  11. #10
    Join Date
    Feb 2006
    Location
    Perth
    Posts
    27,757

    Default

    I've made a few zero clearance throat plates from scratch using 6mm Al sheet.
    I have Al cutting blades but the first slot was just cut with a high tooth count (100TPI) blue.

    One thing they benefit from is a chip/dust escape hole immediately in front of and connected to the slot.

    View2.jpg

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