Tablesaw Throat Insert - What's it made of?

[Tony Haukap]

I have had this Delta dado insert for a number of years...
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I have used it numerous times over the years and just assumed it was an MDF core with laminate on both sides. But, now in looking at it closer I don't think it is MDF.
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It appears to be some sort of wood although it's heavy for it's size.
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I was going to use it as a pattern to make a zero-clearance insert or two out of MDF sandwiched by plastic laminate, but now I wonder if there's something better to use for the core?

[Cary Falk]

Looks like Phenolic.

[Rich Engelhardt]

+1 for phenolic.

Matter of fact, it looks a lot like a Leecraft.

http://www.leecraftzeroclearance.com/

Did you by chance pick it up at Woodcraft? That's where I got one for my Ridgid TS.

[Tony Haukap]

+1 for phenolic. Matter of fact, it looks a lot like a Leecraft.
Phenolic? I don't think I've ever seen that before... I'm going to have to look around for a source for it.
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No. It's a Delta brand insert. I bought it when I got the saw. Now I'm wishing I would have bought a few of the zero-clearance ones, because, except for Woodcraft (which really isn't convenient for me) no one around here sells these inserts.
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Why I'm thinking about it... why does Delta's 36-862 Zero Clearance insert have two slots in it?
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[Cary Falk]

Reveseable maybe. Spin it end for ens and have a fresh area to cut through. Fyi Rockler sells a set of 2 phenolic blsnks so you can make your own.

[lowell holmes]

I make my own inserts using oak. You just plane the wood to the proper thickness and then use the insert that came on your saw for a pattern.

Lower the blade all the way down. Initially, you may have to use a smaller diameter blade.

Insert the new insert in the saw, move the fence so that it will hold the insert in place (careful to not be over the blade), turn the saw on, gently crank the blade up to cut the slot.

I also put an oak splitter behind the blade slot.

It is easy to make inserts for 45 degree miter cuts.

[Joe O'Connor]

I used 1/2 inch Baltic birch ply and made ten while I had the set up.

[Dave Zellers]

Exactly what I did. They work great. Put a set screw in each corner for leveling.

[Jak Kelly]

Or MDF, nice flat area, easy to apply adjustment screws to or add magnets.

[Todd Burch]

Delta inserts have a pin at one end, so I don't think the two slots are to make it reversible.

[Steve Wurster]

Why I'm thinking about it... why does Delta's 36-862 Zero Clearance insert have two slots in it?

Apparently it's so the insert can be used on left-tilt or right-tilt machines. See http://www.deltamachinery.com/faq/387-why-does-the-36-862-zero-clearance-insert-have-2-slots

[Michael Liechty]

I have some scrap Corian I make inserts out of . seems to work well enough.

ML

[Mort Stevens]

Apparently it's so the insert can be used on left-tilt or right-tilt machines. [/url]

Straight from the horses mouth! But why are the slots unequal in length? :)

[David Eisenhauer]

Some things are not meant to be known by mere mortals - you must drop this unhealthy obsession to understand the nature of the extra slot in the insert and go back to your shop and create your own inserts without purchasing them pre-made. Now, before it is too late and the madness takes you beyond retrieval.

[scott spencer]

Or MDF, nice flat area, easy to apply adjustment screws to or add magnets.

I'd want to make sure that the MDF was pretty thick....an insert that flexes leaves a lousy cut.

[Tony Haukap]

Looks like Woodcraft carries 1/2" Thick Phenolic in 11"x15" size. But, the local Woodcraft is a bit of a drive for me. If I'm making the drive to buy the phenolic sheet I'll just buy the Delta insert already made instead of making them myself.

[Rich Engelhardt]

Call before you go. Make sure they have the insert(s) in stock.
Or - you can order through Amazon and save the drive:
http://www.amazon.com/Leecraft-DL-1U-Clearance-Insert-Colors/dp/B0000223VB/ref=sr_1_1?s=hi&ie=UTF8&qid=1406198546&sr=1-1&keywords=leecraft+zero+clearance+insert

[Roger Feeley]

Once you have more than one, you could try renewing the slot by filling it with epoxy. Just tape over the slot, turn it upside down and fill. I've never done it but read that others have.

[Tony Haukap]

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Well, getting a couple of inserts is on my WoodCraft list for when I get there next time.
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So, with some free time on my hands this evening I decided to make one and document it for when I'm old(er) and feeble(r). :) This is for a left-tilt Delta tablesaw... however, I'm curious if someone with a right-titling Unisaw would download the PDF and print it out to see if simply flipping it over it will fit right tilt saws?
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I made a pattern in CAD to locate all the various holes. While not real critical, except for the hold-down screw, I like having a layout pattern that I can use to transfer the locations with a center punch.
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The various screws needed to make an insert...
#10-32 x 1/2"L Set Screw for the 4 leveling feet.
#10-32 x 3/4"L Round Head Hold Down Screw... not really necessary, but I figure when I drop the one that I take out into the base of the cabinet and it gets buried in the sawdust I'll appreciate having a few replacements on hand! :)
#10-32 x 1/2"L Oval Head for the Front-to-Back and Side-to-Side adjustment screws.
#6-32 x 1/2"L I plan on using this for the rear 'Anti-Lift' pin. Will probably have to grind the head off or at least create a flat spot on the top side. I'm not entirely sold on this... I wanted to get just a stainless steel pin, but the home centers didn't have any.
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I'm not sure the photograph does it justice, but the Nevamar #S1049T-Carmen Red plastic laminate is an *exact* match for the Delta inset. No question about it's what they used. The color and matte texture is a perfect match. A very close match is Formica #839-Stop Red... it's color is very, very close, but the texture and matte level is different.
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Now, I'm BIG supporter of USA made stuff... if I have a choice I'll go out of my way to get the USA manufactured item every time. But, how can I support USA manufactures, if they don't even know where it's made!
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Download the insert pattern in DWG or PDF:
AutoCAD DWG file -- http://turbobit.net/ycmclt63og5u.html
Adobe PDF file -- http://turbobit.net/7jibp341qppy.html
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