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Make Your Own Zero Clearance Bandsaw Insert

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

So…. I messed up my bandsaw insert by trying to saw through a cylindrical piece of wood…

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

…now THAT was a shocker!

I was dragging my feet about buying a new one for $15 and then waiting for it to be delivered. I looked around the garage to see what I could make one out of.

I found a 1/4″ thick piece of leftover UHMW plastic from a previous jig I made and was thrilled.

The only thing I wasn’t excited about was trying to get a perfect circle and then setting up my router to make the bottom inset.

WAIT… a perfect circle!?.. My lathe can do that!!

WHAT I USED:

I grabbed my new faceplate and mounted a thick piece of MDF to it for my turning surface. I measured the opening of the bandsaw table and scored the surface of my plastic with my circle compass to be just the right size. TIP: make an obvious impression in the center of the circle with your compass for the next step.

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

Mount sticky tape on the back of plastic…

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

..and use your tailstock to center plastic over faceplate by using the center impression against your live center.

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

I used my thin parting tool to cut the circle just bigger then my scribed edge.

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

Next I crept up on the size little by little using my scraper tool. Once I was getting close I unscrewed the whole faceplate to test the insert in the table opening while it was still attached (remounting/centering back on the faceplate wouldn’t be ideal).

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

Once I got the outer size just right (fit snug in the table) I used my scraper to make the recess. I used my calipers to test the size as I took off a little at a time. I also unscrewed the faceplate several times for test fits. Once my faceplate was sitting flush against the bandsaw table I knew it was seated just right.

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

I used a putty knife to pry the plastic away from the faceplate and remove the tape.

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

Perfect fit!

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

There’s a small indent in the table that would keep the insert from spinning… I heated up a small nail to stick into the plastic edge.

Make your own Zero Clearance Bandsaw Insert - theprojectlady.com

New Vs. Old – I rather like mine!

Stay safe ya’ll!

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