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Woodworking/table saw inserts


Hi Stuart,
I have a table saw that has a factory metal insert.  The insert is sagging by the blade so it's useless except for very wide boards.  I have made a zero clearance insert made of 1/2 inch plywood.  Worked for a while then it bumped up.  I am trying to sand it but I'll be starting to go through the first layer.  I have leveling screws, but the dang plywood keeps warping so the screws can't get it level.  I would have thought the plywood would stay flat.  What kind of material could I use?  MDF might sag...any thoughts would be appreciated.

Hi Robert,

Sorry not to reply sooner but just received the notification email today. Basically when I had a woodworking machines like your table saw we would use a hardwood timber insert. I would make a few at a time because they would wear around teeth of the blade. I wouldn't use MDF due to being a particle board construction. I hope this helps you.



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Stuart Mawle


Now been a carpenter & joiner for the past twenty years in the UK. I can give avice / help on carpentry & joinery, health & safety, woodworking machinery, power tools and suppliers.


I have served an indentured carpentry apprenticeship with a medium sized building contractor doing a wide range of domestic and commercial work. This has included office buildings, barn conversions, building extensions and renovations. During my career, I spent over three years as a wood trades technician at a college. My job involved joinery work, wood maching and helping CITB carpentry & joinery students` pratical projects. Spent three years as a accredited NVQ assessor covering site carpentry and bench joinery. Now I teach my skills to others.

Institute of carpenters

I have city and guild qualifications in site carpentry and purpose made joinery. An indentured apprenticeship Hold the equivalent of a master craftsman status.

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