How I made 5 different designs of zero clearance table saw inserts for the Dewalt

Making five of the most useful zero clearance table saw inserts for the table saw. These are for a Dewalt DW 7491 but the method of constructions should be similar if not the same with other Dewalt table saws such as the DW 745, DW 7480 and many other brands of table saws as well.
The five inserts are as follows:
1.(The Red One) A 90 degree cutting insert for use specifically with plywood with a thin (1/16" kerf) 7 1/4" blade. With this one the blade will not be raised above 1 1/8" in height.
2. (The Purple One) An insert for making bevel cuts. This insert will be for use with both 7 1/4" and 10" blades. Making bevel cuts is not done that often in my shop so I decided to only make one for both blade sizes. I ruffed out the opening with two 7 1/4" blades while going through all the bevel angles on the saw. The opening is larger than needed for it to be an actual zero clearance insert but it should work fine for my needs. This insert is very useful for making bevel cuts when the work piece is turned on end leaving a small amount of the remaining material to ride on the insert. This type of cut is sometimes not possible safely with the factory insert because the opening is so large the remaining portion of the work piece can become completely unsupported.
3. (The Tan One) A general use insert for making 90 degree cuts. This insert has the addition of a splitter attached to the back of it. The splitter is made from a 16 gauge angle bracket that is the perfect matching size of the thin kerf (1/16") diablo blades I usually use. I cut the bracket shorter and removed some additional material to get the splitter as close as possible. The maximum height of a 7 1/4" blade is about 1 3/4" and I probably could have left this much height remaining on the splitter but I ended up cutting it down to around 1 1/8".

Bracket-- https://www.homedepot.com/p/Simpson-S...

7 1/4" Blades that match the brackets thickness--https://www.homedepot.com/p/Diablo-7-...

4. (The Blue One) A general use insert for making 90 degree cuts with a 10" blade with or without the use of the riving knife. On this insert I removed a notch in the rear portion of the riving knife so the insert would still be connected behind the knife. This modification does remove a small portion of the riving knife that would normally be in use when the blade is extended up to it's full height (3 1/4") but I felt it wasn't going to effect the function of the riving knife very much if at all. The alternative would be to join the split on the rear of the insert with a band to keep the riving knife in its full form. Either way would work, I just ended up doing it this way because I felt it was less complicated and possibly an easier method to end up with a precisely flat insert.
5. (The Natural Clear One) A dado insert. This one is for 1/4" import plywood. I make drawer boxes that usually have 1/4" plywood bottoms and this insert is specifically for this purpose. I use a certain combination of three different types of 7 1/4" blades that equal the perfect width dado groove for this application. I also make drawer bottoms with 1/2" plywood and I already have an insert that I use for this. I made a video about it a while back.

Original zero clearance (dado) insert video--   • Видео  

In this first version I removed the factory locking mechanism and installed it on the zero clearance insert. It works good but I find that the lock is really not necessary and decided to omit this feature from the new inserts as it makes them easier to switch out. This one still works great.

The perfect music for this job was "Gimmie five, Distance, Paddle, Haze, and Ethanol" all by David Cutter music.
Music by: @dcuttermusic / http://www.davidcuttermusic.com

More videos on the way!

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Thanks for watching! :)