gee-dub Posted August 25, 2018 Report Share Posted August 25, 2018 I had planned to dovetail one of my phenolic ZCI's to allow replaceable inserts but, never got around to it. Rockler had a clearance sale and the price on this commercial version was fair. I had held off putting it on until I could make some replacement inserts for it. I am still on "light duty" so rather than wrestle a sheet of 1/4" MDF or hardboard I dug some resaw-spoil out of the scrap bin. I milled the scrap to 1/4" thickness and ripped it to width. I used the commercial insert to set the dovetail angle. A Marc Adams style push block works well for this long thin stock. OK, that part fits. I used a magnetic featherboard as a stop to cut the riving knive/blade guard slot. Don't forget the clearance for bevel cuts. Now that I know how to do it I should be able to make a bunch more in a batch once I'm up to it. Like many of these things, making one doesn't really pay. Making a dozen out of scrap however, is way cheaper than paying for them. 2 Quote Link to comment Share on other sites More sharing options...
Chet Posted August 25, 2018 Report Share Posted August 25, 2018 Nice. That looks similar to the one that infinity tools has for the SawStop for $94. How much longer until you get back to full duty Glenn? Quote Link to comment Share on other sites More sharing options...
gee-dub Posted August 25, 2018 Author Report Share Posted August 25, 2018 I'm hoping no more than a couple of more months now. I can putter around but, can't really do anything that strains the old eyeballs; lifting limit of about 20 pounds, no stooping bending at the waist and so forth . Quote Link to comment Share on other sites More sharing options...
wdwerker Posted August 25, 2018 Report Share Posted August 25, 2018 I'm about to make a batch of inserts like that for my 2 Aluminum ZCI plates. Quite a few years ago I was buying some and occasionally making some when I would run out and need them in a hurry. I've got a whole sheet of 1/4" Baltic waiting to make the new ones, hopefully that will last me a long time. Accuracy is key for a good fit which translates into lots of set up time. Great idea on dovetailing a phenolic plate ! I've got one I use with my Micro Jig splitters that isn't very "zero clearance " anymore . Quote Link to comment Share on other sites More sharing options...
Chet Posted August 25, 2018 Report Share Posted August 25, 2018 7 minutes ago, wdwerker said: I've got one I use with my Micro Jig splitters that isn't very "zero clearance " anymore . Quote Link to comment Share on other sites More sharing options...
Coop Posted August 26, 2018 Report Share Posted August 26, 2018 Neat idea on the zci but I like the push block as well. I Googled it but find nothing. Do you have a link to it? Thanks Quote Link to comment Share on other sites More sharing options...
gee-dub Posted August 26, 2018 Author Report Share Posted August 26, 2018 At one minute, twenty seconds here. I had seen Marc and instructors at his school use these tadpole sort of looking push blocks. I have a variety from a push "stick" through Grr-Rippers and this happened to be one of them. The one in this thread is made from a couple pieces of scrap ply laminated together for thickness and then cut to shape. I make my "hook" just shy of 1/4" so I can push 1/4" BB ply and thicker. I do not favor cutting through the block although you will see many do this. I do it now and again but, if the blade is cutting into the block more than an 1/8" you can have it ripped right out of your hand if you fail to keep a perfect feed path. When I know I am going to cut into the block, the block is riding the fence face just like the material. 2 Quote Link to comment Share on other sites More sharing options...
wtnhighlander Posted August 26, 2018 Report Share Posted August 26, 2018 I use a cruder version of that style block. Just a length of 2x6 with a 'heel' screwed the the end (brass screws only). Using such a block sacrifically is great for ripping thin strips, as the block prevents the strip from shooting back. So the strip can be cut between blade and fence, rather than using a reference block on the offcut side and adjusting the fence with each pass. Quote Link to comment Share on other sites More sharing options...
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