Corian zero clearance inserts

[chris99z71]

I got this 24x40 piece of corian from the Habitat re-use center for $7. It made several really nice zero clearance inserts. Notice the holes for set screws. Who would have thought that you could tap corain and it would hold!

I put a dado in the edge and epoxied in two magnets. It doesn't vibrate at all. Pretty proud of myself because I came up with that one all by myself :smile:
I also glued the block under the far side of the insert so that it wont' fly out...probably overkill.

 

[DaveO]

Nice work, you've been rather productive lately :eusa_clap :eusa_clap
And that color is to die for :lol: :lol:

Dave

 

[chris99z71]

Me-productive? Yeah right. Notice that, other than the cabinet from WG's class, these are the only pictures that I've posted of anything that I've made in the past YEAR! :rolf:
Not everybody can turn out 8 beautiful boxes every weekend!

And Dr. Phil said that the green color is slimming for the tablesaw...

 

[DaveO]

And Dr. Phil said that the green color is slimming for the tablesaw...

But posting the picture on an Internet forum adds 10 lbs. :crybaby2: :lol: :lol: :lol:


Dave

 

[Splinter]

Chris I really like your inserts. I need to make some new ones. I used a soft wood on the last one I made and it is getting chewed up where the wood chips are hitting it.

How did you cit it down to size? Did you use regular router bits to shape it?

 

[Canuck]

Great insert there, Chris!!!

I have to ask......how did you cut the profile to fit so well? (Router with a pattern bit?)

Thanks,

Wayne

 

[chris99z71]

It was actually very easy.
First, I ripped it to width on the tablesaw.
Then, I trimmed it to length and put a 45° on each corner.
Next, I put 2 sided tape onto the factory insert and attached it to the corian.
I put a top bearing flush trim bit (pattern bit) in the router table and rode the bearing on the factory insert.
Then, I installed the factory insert with the corian piece still attached back into the saw and slowly raised the blade into the corian. It was necessary to do it this way, because my blade doesn't go down far enough to put the corian in there without touching the blade.
Also, after I removed the tape and installed the corian piece, it was rubbing on the insert on one side. So I removed the blade and put a 0.020" shim from my dado set to push the blade further over to the side that it was rubbing on. Then after removing the shim - I had a little more clearance.

 

[frigator]

Thats a nice insert, but I have been using the same insert for years. After a while it gets wallowed out and I just put tape on the top, turn it over and fill it with epoxy, and wham, I got a new insert.

 

[Monty]

Hey, that's a great tip - thanks Robin!

 

[Canuck]

Thanks Chris. I will have to try and remember the technique.

Thanks for all of the detail!

Wayne

 

[sapwood]

Chris, they don't come any prettier than that! Interesting innovation adding the magnets in addition to the overhang. And a fit that tight, sure won't permit small pieces to hang the blade :icon_thum

Appreciatively,
Roger

 

[McRabbet]

Let me make a suggestion so you (or others making one) won't have the shimming problem that you encountered. Two tricks will make it an accurate opening anda safe cut-through. If you are making a ZCI for a standard kerf blade, install the 1/8" outer dado blade cutter in place of your regular saw blade (I have a 10" tablesaw and an 8" dado set, but 6" will work, too). If you are making a ZCI for a thin kerf blade, install the corresponding chipper blade from your dado set. Run the blade down all the way and put the new ZCI in place. Now move your fence over to cover at lease 1/2" of the ZCI on the right side. Use a safety push block to hold down the left side of the ZCI and slowly bring the blade up through the insert. Works like a charm and no shims needed.

Rob

 

[Travis Porter]

That is a very good idea. I didn't think you could tap corian either.

That Corian is the exact same style and color I helped a friend put in his house.

 

[D L Ames]

Nice job on the inserts Chris. I have the same problem cutting the initial kerf in mine also. I like the method you used to over come that.

D L

 

[junquecol]

Chris, are you a "licensed " Corian fabricator? If not you shouldn't post anything made from Corian according to the manufacturer. Thought I would poke a little fun at you. Nice looking insert.

 

[toolferone]

Corian aka "solid surface counter top".

Now where is that Band-Aid, Kleenex and Q-Tips I needed! LOL

 

[eezlock]

Good looking job on ZCI for the saw....now it is time for a dado throat plate, one for a 45 degree insert as well! eezlock

 

[woodguy1975]

Nice Job Dude!

 

[chris99z71]

Good looking job on ZCI for the saw....now it is time for a dado throat plate, one for a 45 degree insert as well! eezlock

That's why I made 3 :eusa_danc
But I'm using one for wide dados, one for skinny dados and one for a normal blade. I hadn't thought of one for 45's, but I've got a bunch more "solid surface material" (happy now Tom?:lol and it's a good idea!