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.
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| 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
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| The stirring sticks |
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| Power Planing the sides smooth |
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| Gluing the sticks |
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| Adding Spacers |
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