Dewalt Miter Saw Zero Clearance Insert

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Project by pintodeluxe posted 02-09-2011 04:29 AM 23073 views 22 times favorited 22 comments Add to Favorites Watch

I finally made a zero clearance throat plate for my Dewalt 12” chop saw. I don’t know why I never did this before. A scrap of 1/4” mdf worked well. All it took was two layers of tape on the aluminum rim under the insert to bring it flush with the table.
I always used a plywood fixture that screwed to the miter saw if I needed a splinter-free cut. That worked fine if you were only making square 90 degree cuts. This zero clearance insert moves with the table – just like the factory insert- so you can cut at any angle.
The limitation is that it will only prevent splintering on three sides. You can still get some minor imperfections on the edge of the board against the fence. Still, an improvement over my old fixture for most cuts.

-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush

22 comments so far

View Rob Vicelli's profile

Rob Vicelli

109 posts in 3929 days

#1 posted 02-09-2011 04:33 AM

Great Idea!! I will be borrowing that one.

-- Rob V

View AttainableApex's profile


347 posts in 4071 days

#2 posted 02-09-2011 05:18 AM

ya me to, always thought about making one, if it was possible. but now it is i gues

-- Ben L

View missingname's profile


149 posts in 4260 days

#3 posted 02-09-2011 05:23 AM

Well done, I need to do the same to my Dewalt too

View Canadian Woodworks's profile

Canadian Woodworks

702 posts in 4308 days

#4 posted 02-09-2011 05:48 AM

I need to do this also

-- Paul Lemiski, Ontario Canada, Custom Wooden Rocking chairs and tables

View devann's profile


2260 posts in 3930 days

#5 posted 02-09-2011 06:26 AM

If you clamp a piece to the fence you’ll hav no tearout at the fence and you won’t need to turn on your laser ether. The cut at the fence shows were the blade is cutting.

-- Darrell, making more sawdust than I know what to do with

View devann's profile


2260 posts in 3930 days

#6 posted 02-09-2011 06:31 AM

I used to screw a piece to the fence but now I clamp it so I can reposition the MRF/MDO when I need an angle. Make sure and have it a little long to start with because you use it up fast once you start flipping back and forth cutting angles.

-- Darrell, making more sawdust than I know what to do with

View Steven H's profile

Steven H

1117 posts in 4298 days

#7 posted 02-09-2011 06:50 AM

I wish they made insert from heavy metal, it would stay flat.

View Harry_Ch's profile


63 posts in 3914 days

#8 posted 02-09-2011 09:57 AM

Thanks for the idea. Got a new 12” slider and was going to use the full fixture backing but will give this a try.

-- Deeds not Words.

View Ken90712's profile


18066 posts in 4427 days

#9 posted 02-09-2011 11:59 AM

I just made 4 fo them for my table saw this weekend as well. Nice work.

-- Ken, "Everyday above ground is a good day!"

View rance's profile


4279 posts in 4398 days

#10 posted 02-09-2011 02:25 PM

Pinto, I’ve been meaning to do this too. Maybe this will motivate me. :) Thanks for posting.

@ Steven H – Right before you change your blade or get it sharpened, fashion a thick aluminum insert, cut it, then send your blade off to get sharpened. Actually, that sounds like a great idea. Well… I think a nice thick wooden one would be just fine.

-- Backer boards, stop blocks, build oversized, and never buy a hand plane--

View jm64's profile


36 posts in 3920 days

#11 posted 02-09-2011 02:27 PM

Great idea. Think I’ll put that to use.

-- Joe, Cumming, GA

View ratchet's profile


1391 posts in 5025 days

#12 posted 02-09-2011 04:11 PM

I say Brilliant! Or at least very clever…thanks.

View bobber52's profile


2 posts in 4232 days

#13 posted 02-09-2011 04:49 PM

Great idea. I’ll be making some of these this weekend. Thanks for sharing.

-- Bob, Burnsville, NC

View Sierras's profile


37 posts in 4009 days

#14 posted 02-09-2011 05:30 PM

I was cross cutting yesterday on my Dewalt and cussing the tear out . Know what I am doing today. Thanks

View Don Johnson's profile

Don Johnson

743 posts in 4019 days

#15 posted 02-09-2011 05:48 PM

Looks a good idea – and your adjustable left side back guide is pristine (unlike mine – which I forgot to move when doing a bevel cut LOL )

-- Don, Somerset UK,

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