Description
After looking at zero clearance and 45 degree cut inserts for my Dewalt 7485 I decided to design one myself with my CNC router. Unlike other options I found, I wanted to preserve the factory locking dial, as well as the tabs located at the top of the insert that keep it secured.
Starting with half inch MDF, the material wouldn’t hold the tabs well enough, so I experimented with various other wood options, settling on 12mm Sandeply Sande Plywood from the big box store. The plywood has a nice sanded finish and the layers do a better job of providing strong tabs and reduce warping. I included in my design the pocketed screw holes for leveling, but they really aren’t needed as the thickness of the insert fits very well. Also brought from the original design was the finger slot that helps to remove the insert. Finally, I milled out pockets on the bottom to aid in the initial plunge cuts.
These inserts are rigid and fit snuggly in the factory Dewalt 7485 table saw. Each insert is milled, hand sanded, and then sprayed with a clear coat of shellac for protection. As these are not mass produced, they do vary slightly from piece to piece as the plywood has irregularities. However the fit and function remains consistent.
*** YOU MUST REMOVE THE RIVING KNIFE UPON THE INITIAL PLUNGE CUT! Failing to do so will bend and possibly break the tabs. ***
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