Zero (chip-out) tolerance

 

Place thumbtacks onto the ledges,
and then gently lower the insert into
place. Tap it lightly to make
indentations.

 

Add hex screws for leveling. Add
wood screws to one edge and end
for lateral adjustments if the insert
is too loose.

 

Adjust the leveling hex screws to
ensure the insert sits flush with
the tablesaw's top. If it sits too
high your workpieces will catch
on it.

Now level the insert with the tablesaw top

If your insert sits too high, drill or rout relief areas on the bottom where it sits on the throat tabs or rabbet. If your insert sits too low, add leveling screws so you can adjust the fit perfectly from the top. (Use either setscrews or machine screws.) To do this, either transfer the screw locations from the original insert, or use thumbtacks to mark them, photo right. Now drill shank holes, and countersink or counterbore on the top face. Add the screws, center photo right, and then raise or lower them to make the insert flush, photo below right.

Complete Guide to Mastering Your Tablesaw