I need to make a zero clearance table saw insert quickly and efficiently. I start by finding a piece of cherry veneer plywood that is just a little thicker than the existing table saw insert. I can get the width of the new insert by placing the existing insert between the blade and the fence. I can then cut a strip from the plywood that is exactly the right width. Then I trace the shape of the old insert onto the strip of plywood and cut it out on the band saw. Before I fit the new insert in the table saw I need to drill two finger holes, so I can get the insert out if it is too tight. Next I spend some time sanding the new insert to fit. Last I hold the new insert in place with the table saw fence and bring the saw blade up into it to cut a slot for the blade.
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