After purchasing a new table saw, I needed to make extra zero-clearance table inserts. The problem was adjusting the table insert to be flush with the top of the table. I decided to drill oversized holes in each corner, which ended up being about one-and-a-half times the size of my set screws. I countersunk each side, then I filled each hole with epoxy. The countersunk holes are important to lock the epoxy in place from both sides. Then I just drilled and tapped the epoxied holes as normal. Be sure to keep track of the hole’s center for when it comes time to tap. Since these tapped holes aren’t through steel, you should use as long a set screw as possible to utilize as many threads as you can, providing extra strength and stability to the insert.
As you can see from the pictures, I now have my 1⁄2" zero-clearance table insert with a set screw in each corner to adjust the height.
Once the epoxy cures, remove the painter’s tape and drill through the epoxy. Then tap it to accept the set screw.
Once the insert is set in place, use an Allen wrench to adjust each set screw until the insert is flush with the saw table.
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