Sunday, January 2, 2011

Renewing a Zero-Clearance Insert

With the New Years weekend, I spent some time in the shop. Wahoo! I have an ugly spot in the laundry room that needs a maple cabinet so that's today's fun along with some handrails.
The cabinet is made of maple ply and hardwood.  For the ply, I really need the zero-clearance insert to keep the cuts clean.  My insert has some chatter marks around the blade opening from who-knows-what and those make for fuzzy cuts.

To remedy this, I taped over the existing cut...
...flipped the insert, loaded the cut with Bondo, and let it cure.  The next day, ran a new kerf through.
While you can't see a lot of Bondo from the top, the cuts are noticeably cleaner.