Sawstop dado throat plate with replaceable insert

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Project by pneufab posted 12-30-2013 01:38 AM 10906 views 41 times favorited 17 comments Add to Favorites Watch

When I purchased my saw, I purchased the dado cartridge and Sawstop throat plate. Honestly, I haven’t even used it yet since I didn’t want to use the throat plate for one size dado and then have to purchase another the next time I needed a dado (I like the idea of zero clearance for dadoes :) )

I was looking at the Infinity insert (very nice!) but I started thinking, I already have a virgin phenolic, dado throat plate, why not try making it work before plopping down $100 for an aluminum insert that will do the same thing.

Honestly, I surprised that I have not been able to find anyone else who has done one online! All the “hard” machining is already done on the bottom of the plate, it was pretty straight forward!

Now I only plan to use this for dado’s and use the stock plate for regular blades so all of the inserts I made don’t have a slot for the guard/spiltter. I used the regular blade on this first one since that was in the saw. I cut 14 inserts, over-sized, but still need to shape the ends on all of them.

I know this is nothing new (dovetail hardboard insert) but wanted to show that you can use a standard insert and with a little time, make a nice insert.

Thanks for looking!

17 comments so far

View snoman's profile


106 posts in 2976 days

#1 posted 12-30-2013 01:55 AM

very nicely done. I have the same dilemma, with my sawstop and dadoe brake and insert. Now I have that problem solved…thank you

-- "just be yourself, everyone else is taken"....Oscar Wilde

View Lance's profile


428 posts in 3736 days

#2 posted 12-30-2013 02:54 AM

How’d you cut out the large dovetail? That’s basically what it is….. table saw or router table?

-- Lance, Hook'em HORNS! ""V""

View a1Jim's profile


118201 posts in 4787 days

#3 posted 12-30-2013 03:19 AM

Good idea ,how did you do ?


View Sk1pp3r's profile


66 posts in 2983 days

#4 posted 12-30-2013 03:22 AM

Great idea!

View pneufab's profile


131 posts in 4290 days

#5 posted 12-30-2013 03:34 AM

Originally I was planning to use just the router table and I wanted to stop the insert like the Infinity one. I was having a hard time routing it and it seems like no matter how I fed it, it was grabbing. So I went inside and took a break and then “take 2”.

Here’s what I did:

Put a full dado stack in the saw with cartridge and adjusted the spacing on the brake (first time doing that, a bit tedious). I leveled the insert and ran the full stack as high as it would go into the insert so I knew what I had to work with for maximum width.

After that I removed all the hardware and set screws from the insert.

Once I had the opening from the stack, I planned to make a lip of about a 1/4” for the insert to sit on it with a full stack.

I started routing out the waste with a straight bit and trying to stop it, but I was having a hard time. Eventually I decided to just run the insert the full length of the insert and ran it through the table saw with a rip blade and removed the waste. If I had the dado installed, I would have just used that.

After removing the waste and having 90° edges, I just set a dovetail bit in the router table and started taking light passes until the depth and sides were angled.

I made a few test cuts for the inserts and started cutting up some 1/4” tempered hardboard at a 14° angle.

The only piece that I had to remove from the stock insert was the set screw for the front to back slop (see the last picture) The original insert was a little sloppy, but when I cut and sanded the hardboard, I just took a few extra seconds to make sure it fit tight and it took out any play front to back.

I hope that helps.

Thanks guys!

View lanwater's profile


3113 posts in 4144 days

#6 posted 12-30-2013 05:18 AM

Thanks for the great idea!

-- Abbas, Castro Valley, CA

View gtbuzz's profile


427 posts in 3651 days

#7 posted 12-30-2013 06:51 PM

Absolutely wonderful idea, definitely going to do this one for myself.

View Mean_Dean's profile


7057 posts in 4357 days

#8 posted 12-30-2013 07:51 PM

Great idea! When I get a dado set for my Sawstop, I’ll have to “borrow” your idea!

-- Dean -- "Don't give up the ship -- fight her 'till she sinks!" Capt James Lawrence USN

View Northwest29's profile (online now)


1711 posts in 3700 days

#9 posted 01-03-2014 01:44 PM

Nice idea. Something else for my project list. (-:

-- Ron, "Curiosity is a terrible thing to waste."

View tyvekboy's profile


2128 posts in 4223 days

#10 posted 01-04-2014 03:35 AM

Great idea that Iʻm going to have to try for my saw.

Thanks for sharing.

-- Tyvekboy -- Marietta, GA ………….. one can never be too organized

View Rob Mammen's profile

Rob Mammen

67 posts in 3901 days

#11 posted 01-08-2014 03:01 AM

This is great and gives me some good ideas. next time i have some free time I know what my next little project is going to be. thanks for sharing this with us.

-- Rob, You have failed if you have not tried.

View Bobcdn's profile


8 posts in 4082 days

#12 posted 01-08-2014 07:30 PM

Shared your insert idea over at the Canadian woodworking site. Will have to copy this once I get my shop set up.

View Rob's profile


704 posts in 4280 days

#13 posted 07-26-2014 07:34 PM

Nice job. Looks like you used the dado throat plate. Do you think it would work as well with the standard throat plate, or would that be too weak since it’s split on the back side?

-- Ask an expert or be the expert -

View pneufab's profile


131 posts in 4290 days

#14 posted 08-03-2014 12:27 AM

Rob – Personally, I would think it would be a little too flimsy with the standard insert and the split in the back.

View Plain's profile


157 posts in 1908 days

#15 posted 07-14-2016 05:39 AM

If I understand right the left and right halves of the phenolic plate are connected by very thin and narrow bridge? Isn’t the whole construction a bit flimsy ?

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