Table Saw Insert

Table Saw Insert

New table saw insert using polypropylene, (Black Plastic). Wasn’t sure if this was going to work. I need a little more then 1/2″ thick material and I had this plastic laying around. So I figured it might work if I used epoxy to glue two pieces together. I will be more interested in the long term effects in this matter then the process of making a table saw insert. Here’s how I did it and I’ll keep you posted on the results.

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vlcsnap-00002When you have a lot of extra plastic laying around you can find just about anything to build.
vlcsnap-00004-1Mixing epoxy to glue these two strips together.
vlcsnap-00006I used my homemade clamp for segmented rings to apply lots of pressure.
vlcsnap-00009Using double sided tape. I taped my old insert to the new blank.
vlcsnap-00010Cut off the corners free hand, be careful doing this free hand. If your not comfortable use a miter set at 45 degree.
vlcsnap-00011Using a pattern bit, I followed the old template to cut the new one. Speed, you may want to pay attention if using plastic you don’t want it to melt.
vlcsnap-00012Two stop blocks setup to rout a groove where the blade is going. Plunge the insert into the router bit and slide it to the stop.
vlcsnap-000143/4″ hole was drilled for removal of the insert after installed.
vlcsnap-00015Using hot glue on my insert tabs allows me to level the insert.
vlcsnap-00017After the glue sets you can remove the insert to make sure the glue bonded to the insert not the table.
vlcsnap-00018The best part is sliding the fence over the insert, but not the blade, turn the saw on and raise the blade up into the insert to cut a new slot.