One of the things that I did not like about my miter saw was not having a zero clearance plate for the saw and I felt like it was leaving me with very rough cuts. I pulled the original out, which was 0.250" in thickness. I started looking around for something of this thickness and started to think I would have to plane a board down. I will still make a zero clearance fence for the back, but that is much more straightforward and often may be sacrificial.
Then I saw something that measured 0.249" thick: a wooden 5-gallon paint stirrer from HD. Below is the result.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_MtJ7haW8suntk0z4GKK6CQqzXkR2LT6V9WB6MiRVWfYwBDlMmQxWVy5xHR-ePEzboYWidSbcURPViHNE3XFumE6LAR6-t7niWUTYV6YheadJNIa9cgMN3vcpeWzJCXuDHbV-o0IDnNmO/s1600/zero_1.jpg) |
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.
Enjoy,
Garth
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd1aA2FauN_FWmAWuFYFik07yW7bFNVFCfjmYWsa_tRpGPyPFw-8TD3yGcf8AMQX3WIJ-Z7XikSTcwfQWagaxMt3tB877Ta2tRoQEmplM6gTHhva_3nNhtoXlA5nYakHSKkf-BoYXQUUGp/s1600/zero_2.jpg) |
The stirring sticks |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieh4y7O81_u2Phlc2C0Gco-ImGhwY90_MDvnCDJHCFVwFuxTq6QNf7hpxUrNFa4n83Zzxwl_pJBsxjFlaT_p60ZTBchcRBTPT0rG77ZSpr7TI6LkbJ69cls-tYfG5GKKTOas8wTWxCVYZA/s1600/zero_3.jpg) |
Power Planing the sides smooth |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmD7AX7pEV-fmRH1wb0GcS7PBVipWzcCs5XeEzKDTCanu_Mxb-7FN3hG43gQm9oU8Ki1OXPWstMJIFKCpDIZvdBjWFe156ndEjMCwH-F78NF-YbRjaNCDye6q-z1Xqsl2KcWAj13T4UGLf/s1600/zero_4.jpg) |
Gluing the sticks |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9CJme7bRJnb0H0xx7PvhvJYzsONQgG2yQBuThCF2DtDbGbhB6PsVuodM35NdtAhbZ5hsbngUs9Hhok0LJDkxZc2aWbNF5gx4ZgdVEfCP9uOsuNalDt_LDg6OSQCUm0KFP8ebTHkkSwego/s1600/zero_5.jpg) |
Adding Spacers |
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