Jigs and Such #1: PCB220TS Zero Clearance Insert

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Blog entry by Chris Moellering posted 12-26-2012 08:16 PM 13074 reads 1 time favorited 2 comments Add to Favorites Watch
no previous part Part 1 of Jigs and Such series Part 2: Router Insert Modifications »

I picked up my first-ever table saw about three months ago, a Porter-Cable 220 Job site saw. (review)

I have been quite happy with it, but it does have a few drawbacks. Probably the biggest, and most often-noted is the funky metal insert next to the blade.

This design does not allow for standard zero-clearance inserts to be used, and no one makes one for this saw.

Having got some cash from Santa, I have my eye on a dado blade set, but only if I can make an insert to work well with it….an afternoon off from work, the rest of the family parked in front of the TV…to the man cave!

Found a scrap of 3/4” plywood that was close to the right size, so I started trimming it down.

This is what the underside ended up like. The one extra half circle can be attributed to this coming off the scrap pile. ;-)

Because the blade does not lower very far below the surface, I couldn’t to a typical solid insert and then slowly raise a running blade into it. (At least not until I get something different than a 10” blade.)

I rummaged around and found a couple of screws the same size as the leveling set screws for the original insert and used them to hold the new insert in place.

Overall, I’m happy with it as a proof-of-concept. It is much less “flexy” than than the factory insert.

Now to order that dado stack and then work on a true ZCI version or two.

-- Grace & peace, Chris+

2 comments so far

View NormG's profile


6508 posts in 4218 days

#1 posted 12-28-2012 01:39 AM

Great idea for the plate update

-- Norman - I never never make a mistake, I just change the design.

View dustyal's profile


1322 posts in 4690 days

#2 posted 04-08-2013 04:29 PM

Thanks… I need to make something similar for my bench top Rigid.

-- Al H. - small shop, small projects...

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