R4512 zero clearance inserts

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Project by Hazardpay posted 01-23-2018 03:50 AM 2905 views 5 times favorited 16 comments Add to Favorites Watch

I have attempted about 4 times to make some good quality zero clearance inserts for my R4512. They have always had something I didn’t like about them. Finally…I think I got it. Made from 5\8 mdf, the areas for the leveling pads are routed to 3\16. Aluminum tabs to prevent lift off, predrilled and CA glue with stainless pan head screw. Small washer for the magnetic catch. These things are finally perfect.

16 comments so far

View lizardhead's profile


653 posts in 3640 days

#1 posted 01-23-2018 08:44 AM

And, you made extras to pass around.

-- Good, Better, Best--Never let it rest---Always make your Good be Better & your Better Best

View Just_Chuck's profile


11 posts in 1044 days

#2 posted 01-23-2018 02:00 PM

Good job. I like the way you handled the retention clip…just might steal that idea.

-- ...sometimes, just makin' firewood.

View PPK's profile


1767 posts in 1608 days

#3 posted 01-23-2018 02:02 PM

One tip I’d offer if you don’t already do this: MDF is not terribly resistant to the abrasion of the wood chips that the blade creates, and the inserts will eventually become larger around the blade. You can slow down this effect or stop it by dripping CA glue (super glue) around the slot. It strengthens the fibers… Great work!

-- Pete

View Richard's profile


11309 posts in 3832 days

#4 posted 01-23-2018 02:19 PM

Nice Pile Of Inserts!


-- Richard (Ontario, CANADA)

View splintergroup's profile


3846 posts in 2021 days

#5 posted 01-23-2018 03:46 PM

I really like the extra steps you took, fine work!

Having a pile of spares is smart thinking.

For my Unisaw, I usually just use a flat piece of 1/2” BB plywood, but I’m considering placing several gussets on the underside to stiffen/flatten it up. Basically the same thing you did by recessing your tab surfaces.

View helluvawreck's profile


32122 posts in 3665 days

#6 posted 01-23-2018 03:51 PM

These do look very consistent with each other and it looks like they are quality made. Nice work!

helluvawreck aka Charles

-- helluvawreck aka Charles,

View doubleDD's profile


9525 posts in 2842 days

#7 posted 01-23-2018 04:17 PM

Nice job with these. A good reminder that I need to make a couple.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View LDO2802's profile


167 posts in 1229 days

#8 posted 01-23-2018 04:53 PM

Tell us how it turned out. I did the same thing for mine and found that if you accidently pushed to hard on the insert the MDF bowed where it met the adjuster pads.

View pottz's profile


10240 posts in 1783 days

#9 posted 01-23-2018 07:33 PM

man those look factory made,nice job.ill send in my order right away-lol.

-- working with my hands is a joy,it gives me a sense of fulfillment,somthing so many seek and so few find.-SAM MALOOF.

View James's profile


142 posts in 2586 days

#10 posted 01-23-2018 08:43 PM

How did you cut/shape them? I just ordered my second for dado blades and I’d rather make my own but I don’t have a bandsaw currently and a jig saw doesn’t make very nice cuts.

-- James - Semper Fi

View ScottKaye's profile


782 posts in 2752 days

#11 posted 01-23-2018 09:14 PM

How did you cut/shape them? I just ordered my second for dado blades and I d rather make my own but I don t have a bandsaw currently and a jig saw doesn t make very nice cuts.

- James

My guess is CNC.. looks to perfect otherwise!

-- "Nothing happens until you build it"

View Hazardpay's profile


44 posts in 2400 days

#12 posted 01-23-2018 10:24 PM

James- I really appreciate the CNC comment and I really wish I had one. Created a 2 piece pattern. And used a router with pattern bit. The trick was the time I took to build the pattern. I can make one of these from scratch in about 5 minutes now with the patterns. That was my goal.

View Gittyup's profile


207 posts in 2755 days

#13 posted 01-23-2018 11:41 PM

Nicely done. I made some for my saw a few years back. Not quite as nice as yours, but they work good. I too used a router pattern bit. It works, but man I hate routing MDF. The dust is just horrible.

-- tel

View bigJohninvegas's profile


788 posts in 2261 days

#14 posted 01-24-2018 02:19 AM

Very nice. I have always wanted to try making my own. Saved this post a long time ago thinking I would give it a go.

I had bought several lee craft plates, and have never got around to it. Getting close to needing more.
I will have to give it a go.

-- John

View Hazardpay's profile


44 posts in 2400 days

#15 posted 01-24-2018 02:34 AM

John, I have looked at that pic about a hundred times. I knew there had to be a way to produce easily

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