Zero clearance insert for Byrnes Cross-cut sled

[RichardG]

As I was beginning to use my new saw, I was getting some tear-out when using the cross-cut sled with a 3" 70T blade. So I decided to make a zero clearance insert.

 

Using some 1/8" hardboard and plywood, I came up with this:

 

 

I made a quick jig for my scroll saw to allow me to cut the slot for the angle fence. The fixture just lifts in and out, the base is a snug fit front to back and the plywood at the rear stops any sideways movement.

 

The stop was then 1/8" too a tall so I made a small fitting from 1/16" plywood and boxwood to raise it up. 

 

 

The original thumbscrew was too short so I replaced it with a new brass one. Although I didn't need to, I replaced the others to match.

 

I also needed a longer pivot screw for the angle fence but the main adjusting screw was fine.

 

This of course means I've lost 1/8" from the maximum thickness of cut. Most of the time this will not be an issue but I have additional 4" blade if I need it.