I recently upgraded my tablesaw with a new riving-knife attachment, an addition that meant I also needed all new zero-clearance inserts. Fortunately, I found a great, quick way to level a new insert. To make the inserts, I cut blanks to length and width, then used a factory insert as a pattern to rout them to perfect size. Here’s the clever part: To install one of the new inserts, I kneaded four pea-size balls of quick-setting plumber’s epoxy and placed them on waxed paper on the corners of the saw’s insert support ledge. I then set a blank insert in the opening on the epoxy balls and, with a straightedge spanning the insert, gently pushed the blank down until it was level with the saw table. After 5 minutes I removed the blank, with the epoxy adhered to it, and set it aside to cure overnight. The result is a perfectly fitting zero-clearance insert that’s level with the table.

Lenny McHugh, Pottsville, MN

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