How To Make Table Saw Insert Plate
If you own a table saw, you know how important the insert plate is. It provides support for your workpiece and helps prevent kickback. However, over time, your insert plate may become worn or damaged. Instead of buying a new one, why not make your own insert plate?
Making your own insert plate is not as difficult as it may seem. All you need is some basic woodworking skills and a few tools. In this article, we will guide you through the process step by step, so you can have a custom insert plate that fits your table saw perfectly.
First, you’ll need to gather the materials. You can use plywood or MDF for your insert plate. Plywood is more durable, but MDF is cheaper and easier to work with. Measure the dimensions of your table saw’s opening and cut the plywood or MDF to size. Make sure to leave a little bit of extra material for fine-tuning later.
Next, you’ll need to mark the location of the blade on the insert plate. Use a pencil to trace the outline of the blade onto the plywood or MDF. Then, carefully drill a hole inside the outline so you can insert your jigsaw blade. Cut along the traced outline, following the shape of the blade. Take your time and make sure the cut is smooth and accurate.
Choosing the Right Material
When making a table saw insert plate, it’s important to choose the right material that will provide durability and stability for your woodworking projects. Here are some factors to consider when selecting the material:
- High-density phenolic: This is one of the most popular materials for table saw inserts due to its durability and resistance to temperature changes. It is a self-lubricating material that reduces friction and helps prevent kickbacks.
- Aluminum: Another common choice for insert plates is aluminum. It is lightweight, yet strong and provides excellent stability. Aluminum is also resistant to rust, making it a durable option for your table saw.
- MDF (Medium Density Fiberboard): MDF is a cost-effective option for those on a budget. It is a dense and stable material that can be easily machined to fit your table saw. However, MDF is not as durable as phenolic or aluminum and may warp over time.
- Plywood: Plywood is another budget-friendly option for a table saw insert plate. It is a versatile material that can be easily customized to fit your table saw. However, plywood may not be as durable as phenolic or aluminum, and it may warp or deform under heavy use.
- Other materials: There are other materials available for table saw insert plates, such as acrylic or polycarbonate. These materials are less common but can provide good stability and durability for your woodworking projects.
Ultimately, the material you choose for your table saw insert plate will depend on your budget, personal preference, and the type of woodworking projects you plan to undertake. Consider the factors mentioned above and choose a material that will provide the best combination of durability, stability, and affordability for your needs.
Measuring and Marking
Before you start making a table saw insert plate, it’s important to measure the dimensions of your table saw opening accurately. You’ll need a measuring tape or a ruler to get the precise measurements.
Start by removing the existing insert plate from your table saw and place it on a flat surface. Use a measuring tape to measure the length and width of the opening. Write down these measurements as you’ll need them later.
Once you have the measurements, you’ll need to transfer them onto a piece of material that you’ll use to make the new insert plate. It’s important to choose a material that is sturdy and durable, such as plywood or acrylic.
You can use a ruler or a straight edge to draw the dimensions of the opening onto the material. Make sure to double-check your measurements and take into account any curves or bevels in the opening.
After marking the dimensions, use a jigsaw or a coping saw to carefully cut along the lines. Take your time and make precise cuts to ensure that the new insert plate fits perfectly into the table saw opening.
Once you have cut out the insert plate, test it by placing it into the table saw opening. It should fit securely and sit flush with the table surface. If it’s too big, you may need to trim the edges slightly with a file or sandpaper.
Optional: Adding Leveling Screws
If you want to ensure that your insert plate is perfectly level with the table surface, you can add leveling screws. These screws allow you to adjust the height of the insert plate to match the table saw surface.
To add leveling screws, flip the insert plate over and mark the locations where you want to place the screws. Drill small pilot holes at these marked locations. Then, insert the screws and tighten them until they hold the insert plate securely in place.
| Material | Dimensions |
|---|---|
| Plywood | 24″ x 16″ |
| Acrylic | 24″ x 16″ |
It’s important to note that the dimensions provided in the table are just examples. Make sure to measure your own table saw opening to determine the exact dimensions you’ll need for the insert plate.
Cutting and Shaping
The first step in making a table saw insert plate is cutting and shaping the material. You can use various materials for the insert plate, such as plywood, MDF, or phenolic resin, depending on your preference.
Start by measuring the dimensions of your table saw’s throat plate opening. This will determine the size of the insert plate you need to make. Use a tape measure or ruler to ensure accurate measurements.
Once you have the measurements, mark them on the chosen material using a pencil or marker. Make sure to add a few extra millimeters or inches to each side for a snug fit. This will prevent the insert plate from moving or rattling during use.
Next, use a jigsaw or a circular saw to cut out the shape of the insert plate. Follow the marked lines carefully for a precise cut. If you’re using plywood or MDF, ensure that the blade is sharp and cutting smoothly to avoid splintering.
After cutting out the initial shape, you may need to refine the edges for a perfect fit. Use sandpaper or a router with a flush-trim bit to smooth out any rough edges or uneven surfaces. Take your time and make sure the insert plate fits snugly in the throat plate opening.
Finally, if desired, you can use a router to create any additional features on the insert plate. For example, you might want to add leveling screws or a finger hole for easy removal. Use a router with a straight bit to cut these features, following your design carefully.
Remember to wear appropriate safety gear, such as safety glasses and gloves, when cutting and shaping the insert plate. Always follow the manufacturer’s instructions for your tools and exercise caution throughout the process.
Installing the Insert Plate
Once you have created your insert plate according to the measurements of your table saw, it’s time to install it. Follow these steps to properly install the insert plate:
Gather the Necessary Tools
Before you begin, make sure you have all the necessary tools for the installation. You will need a screwdriver, screws, and possibly a wrench, depending on the screws used for your specific insert plate.
Remove the Existing Insert
Start by removing the existing insert from your table saw. Carefully lift the existing insert and set it aside. Set it on a clean and flat surface to avoid any damage.
Align the Insert Plate
Place the insert plate on the table saw, aligning it with the opening. Make sure it fits snugly and that the edges are flush with the table. Take the time to double-check the alignment to ensure accuracy.
Some insert plates come with leveling screws that allow you to fine-tune the height and level of the plate. If your insert plate has these screws, adjust them as needed to achieve a perfect fit.
Screw in the Insert Plate
Once the insert plate is properly aligned, use the screwdriver to screw it into place. Start by driving in the screws at the corners of the plate to hold it securely. Then, add additional screws along the edges, spacing them evenly to ensure stability.
If your insert plate has additional holes for leveling screws, insert and tighten them using a wrench. This will help to further stabilize the plate and prevent any movement during use.
After the insert plate is securely attached, give it a final check to make sure it is level and flush with the table. Make any necessary adjustments before moving on to using your table saw.
With the insert plate properly installed, you are now ready to use your table saw for precise and accurate cuts. Remember to always practice safe operating procedures when working with power tools.
Questions and answers
What materials do I need to make a table saw insert plate?
To make a table saw insert plate, you will need a piece of plywood or plastic material, a pencil, a jigsaw or router, screws, and a drill.
Can I use any type of material for the table saw insert plate?
While plywood and plastic are commonly used materials for table saw insert plates, you can use any material that is sturdy and flat enough to fit securely in your table saw.
Do I need any special tools to make a table saw insert plate?
You will need basic tools such as a jigsaw or router, a drill, and screws. Depending on the materials and design you choose, you may also need sandpaper, a file, or a router bit.
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