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ZERO-CLEARANCE/DADO TABLE SAW INSERT
INSTRUCTIONS
WARNINGS
• Disconnect saw from power source before fitting or removing insert.
• Always wear eye protection.
• Be sure blade is NOT in contact with insert before switching on.
• Do not attempt to tilt the arbor while the blade is in the insert! The blade will bind, causing severe damage
and possible injury! For beveled cuts, a separate, dedicated insert must be prepared. Pre-set the angle
and then proceed as instructed below.
• Insert must be securely clamped down with a board before plunging blade up through it to cut kerf.
• If using blade stabilizers, check clearance before raising blade.
INSTALLING AND FITTING YOUR INSERT
1) Lower the blade completely.
2) Place insert in throat opening, back end first, so that anti-lift pin engages under rear edge of tabletop.
Initially, the insert should be too long; and hit on the front “fitting bumps”.
3) Using medium grit sanding block, LIGHTLY sand all four fitting bumps. Also, lightly bevel the bottom
edges of the FRONT bumps to ease entry. Sand, test, repeat — to gradually “sneak-up” on snug, yet eas
-
ily removable fit. Once you have achieved a TIGHT, WEDGE fit, work only FRONT bumps from then on.
4) Back out the four leveling screws, until insert is stable, and flush with tabletop.
5) To remove insert, bump the heel of the your hand on rear of insert; front of insert should pop up slightly.
Alternatively, a 3/4" finger hole can be bored near front of insert to facilitate removal.
6) SPLITTER: If the insert is to be used with a splitter, you will need to finish cutting out the pre-routed
optional splitter slot, using a saw or router. Break sharp edges with fine sandpaper.
CUTTING THE BLADE SLOT (KERF)
1) Check that insert is fitted properly, and that blade is clear. Using a stick, reach under the table and rotate
the blade manually to check for blade clearance.
2) Fully cover the insert with a board, and clamp at each end to the table saw top.
3) Re-connect power to saw. Switch on, slowly and cautiously raise blade up, to cut its way through the
insert. KEEP HANDS OFF OF TABLE TOP, STAY CLEAR AND WEAR EYE PROTECTION. Raise blade
to maximum height at this time.
4) Lower blade, turn off saw, and remove board. Your insert is now ready for use!
IMPORTANT TIPS FOR USE
• Only recommended for use with carbide tipped cutters.
• DADO BLADE - Use same procedures outlined above, but use additional caution due to excessive mate-
rial being machined from insert during the slotting procedure.
• Under certain conditions, an undesirable scraping noise may be generated by your saw blade. Planer type
blades and/or excessive arbor run-out, and/or blade distortion, may be causing intermittent contact with
the insert slot. To remedy this, remove the insert and slightly widen the slot using a file or sanding paddle.
• Ideally, a separate insert should be used with each blade, dado stack, or angle set-up. This will insure a
true “zero-clearance” effect and give you maximum benefit from your inserts.
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