6'' Digital Caliper Digital caliper has 50% larger display, giving you easy-to-read numbers and .0005" accuracy. Can be used for inside, outside and depth measuring. Inch or metric display can be easily converted at .. 6'' Digital Caliper

• Band saw or scroll saw
• Router with a flush trim pattern bit

Pattern Flush Trim Router Bit Top quality bits that meet the high demands of Rockler Woodworking and Hardware... Pattern Flush Trim Router Bit

• Double back tape

Measure to get the thickness for the wood insert

Plane down the piece of wood to that thickness.
Place the metal insert upside down on the wood and trace around it leaving about 1/16" to 1/8" clearance all the way around.

Trace about 1/16" to 1/8" wider than the insert

Cut out the insert staying just outside the line.

Cut close to the line but on the outside

Double back tape the metal insert to the cut out piece of wood.

Three pieces are plenty

Using a flush trim pattern bit in your router copy the metal insert to the wooden one. You can do this with either a top bearing or bottom bearing bit.

Pattern match the metal insert

Remove the metal insert and see how it fits in the tablesaw. If it's too tight just some light sanding should make it fit.
If you find that the support tabs for the insert on the tablesaw are not even you can use countersunk screws in the bottom of the wood insert to level it.
Put the insert into the tablesaw with the blade turned all the way down. I put my fence over part of the insert to help hold it in place.

Raise the blade through the insert

Slowly raise the blade through the insert until you get to the desired height. Go a little beyond and then back it down to where you want it.
For ripping blades it's a good idea to put a spreader into the insert. Cut a slot the width of the saw blade into the out end of the insert. Cut a piece of hardwood the thickness of this slot.

Glue in a spreader to prevernt wood buning

Radius the end that is toward the saw blade and glue it into place. This will help reduce any burning if the wood tries to close up after it's been cut.

Make a zero clearance insert for every dado with combination you plan to use and mark each insert with the with or blade combination.

That's about it. We hope you liked this project. If you build it and your friends ask where you got such a clever idea, please tell them that you got it at RunnerDuck.com.