December 19 2008 20:06
I made the zero clearance insert for my table saw from MDF. The Craftsman saw I have has a funny shallow lip around the inside of hole. It was really kind of a pain because the material left on the ouside of the insert was rather thin. The holes were put into the insert to improve air flow to the lower dust chamber on the saw. The blade has a plastic enclosure beneath the table the completely surrounds the blade. I sealed this enclosure nearly air tight using foam. I needed to cut the holes in the zero clearance insert in order for the dust collection to have the necessary air flow.
The splitter in the rear of the blade is made from one of those spacers you use when installing laminate flooring.