DeWalt DWE7485 Table Saw Zero Clearance Insert

prusaprinters

<p>I wanted a zero clearance insert for my DeWalt DWE7485 jobsite saw and printed another I found online but it didn't fit my saw very well so I set out and whipped this one up. The insert fit well enough and was fairly straight forward to level with some M3 screws from the underside. The biggest trouble I encountered with using this has nothing to do with the insert at all. I have this material in ABS and tried several prints when dialing the dimensions in and always had some warpage. Not while printing mind you it stayed flat as can be stuck to the bed but as it cooled it always developed a bow in it. I tried cooling it very slowly using the heated bed to gradually lower temp and that helped as it came off still flat. I even used weights spread across it while cooling. The next morning though it had a curve to it again. The reason I'm mentioning this is two fold; this explains why there are 2 version of the stl's the thinner version was an attempt to minimize the pull or tug of the ribbing to aid in the prevention of warpage. It didn't seem to make a difference though. The other reason I mention it is more of a cautionary tale to print this in a less warpy material. I plan on reprinting this in a PLA or equivalent when I get the color I want.</p><p>&nbsp;</p><p>To install the usual steps apply, lower the blade all the way down and insert this plate. Turn the saw on and slowly raise it up to cut the zero clearance opening. I can hear what your thinking there's already a slot why…. that slot is just under an 1/8" of an inch so it'll install over the blade if you don't lower it but it'll be very tight. The point here was to make it close enough to need a shave to be perfect without generating a giant wad of molten plastic along the edges.</p><p>&nbsp;</p><p>Side note if someone knows what I did or could do with my rib design to aid or prevent the curling affect induced by stress let me know.</p>