Here is what I did to make table saw zero clearance inserts for my Porter Cable PCB270TS

First I cut some scrap ½ inch plywood to the same basic dimensions as the factory insert. Using small screws attached the insert to the wood:

I then trimmed the corners and using my router table and the factory insert as a guide, cleaned up the ½ inch plywood to have the same outside dimensions as the factory insert.

I then used my template to mark the leveling screw holes. I drilled the holes from the top, if there is any tear out it will be on the bottom.

I then routed out 3/8 inch of material from the bottom leaving 1/8" for the top. I used the factory insert as a template. I went 3/8 inch in around the ends and ¾ inch in from the sides.

This is not necessary, but I put on a coat of schlack and sanded them down.

I lowered my blade all the way down, inserted the insert, placed the fence over it and slowly raised the blade slowly until it was completely raised and through the insert. I had to use a 7 ¼ inch blade and then a 10 inch. The 10 inch would not lower enough to allow the insert to seat. Make sure your blade will not hit the fence when it comes up.

I like the knife behind the blade. So using a ¼ inch bit, the smallest I have. (Wish I had an 1/8 inch) I drilled out an area long enough for the knife.

And there you have it:

Hope you enjoy!

Keywords: table-saw, saw, tools, zero clearance, insert, table, plywood, woodworking, DIY, Porter Cable, PCB270TS