I am resurfacing my workbench with 25mm hardwood ply. I am inverting an up/down router and tablesaw into it (between tracks). I want to use thinner insert plates (for the zero clearence saw and so that both tools can raise and lower) What material for the inserts should I use? I want a max. of 10mm thick, prob. about 150 x 150mm and 100 x 150mm. Would MDF be smooth and strong enough, some sort of formica faced material ... alternative suggestions? Thank you in advance.

  • 1
    Hi, welcome to StackExchange. If you've seen enough out there to know what a zero-clearance is and that they can be made by the user themselves then you'll have seen examples of what they can be made from, or even are typically made from..... If your application is slightly different to the typical ZCI however then you might need to describe it in more detail, or provide a quick sketch or two (with a photo of your saw if that would help), to give a better idea of what you're doing.
    – Graphus
    Feb 1, 2021 at 12:41
  • Thanks Graphus; I'll add some more detail later; what is ZCI?
    – SaltyBob
    Feb 1, 2021 at 15:15
  • Ahhh!!! ... Zero Clearence Insert?
    – SaltyBob
    Feb 1, 2021 at 15:16
  • The example I was looking at was this one .... but I couldnt identify the material used for the inserts? m.youtube.com/watch?v=skMNEDn52Ys&feature=youtu.be
    – SaltyBob
    Feb 1, 2021 at 15:19
  • After a bit more looking, I think some laminate flooring should do the trick. I'll hunt around for a pack that is thin/strong/smooth enough then inset flush to the workbench with countersunk machinehead screws & nuts (for easy removal). I'll post some pictures when done.
    – SaltyBob
    Feb 2, 2021 at 7:24


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