Then I saw something that measured 0.249" thick: a wooden 5-gallon paint stirrer from HD. Below is the result.
|Final Zero Clearance Insert|
The next pictures show some of the progress. The first pictures shows what I started with. I first power planed the sides smooth with my HF power planer (A great $40 purchase!) as I did not want to use my larger joiner with such a small item. I clamped them together with glue and used an air compressor for extra weight to keep them flat. After sanding, the thickness had fallen, so I had to use some extra spacers of tape and plastic strapping wrap used on a box. It started to get late and I was tired. I should have gotten some new screws and countersunk them, but the stores were closed. With that, I just used a forstner bit for the bolt to fit.
|The stirring sticks|
|Power Planing the sides smooth|
|Gluing the sticks|