One-Size-Fits-All Table Saw Insert

Switching between a standard blade and a dado blade on the table saw also means switching the throat insert. On top of that, different size dado blades require matching zero-clearance inserts. So rather than keep a stack of inserts on hand, I came up with a shop-made, one-size-fits-all insert.

The insert starts with a ¼″ hardboard base layer cut to fit the saw’s throat opening. Cutouts in the base accommodate a standard blade and any size dado blade (drawing above).

The upper, hardboard layer (glued to the base) consists of two, rabbeted cap pieces separated by a space that holds interchangeable filler strips. You can make a different zero-clearance filler for each width of dado blade, as well as a standard blade.

After changing blades, you simply slide in the appropriate filler and you’re ready to go. The real kicker is that the fillers are cheap to make or replace and don’t take up much storage space.

Good Woodworking,

Ted Raife
Online Editor, Woodsmith

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