A zero-clearance insert with a splitter is one of the big keys to safely and accurately ripping thin strips. The insert prevents a strip from getting trapped between the blade and the opening. And the splitter keeps the strip from binding on the blade. (See information on a Freud rip blade).

To make a new insert for your table saw, you’ll need to start with a blank that matches the thickness of your stock insert. (Note: If the material is thinner, you can add screws to the bottom so you can adjust it perfectly flush with the saw table.)

After tracing the outline of the original insert on the blank, cut away most of the waste (Figure 1). Then use a flush trim bit in the router table to create an identical insert (Figure 1a).

Ripping a slot in the new insert is just a matter of carefully aligning the fence with the edge of the original insert and making a stopped cut, as in Figure 2. Finally, cut a hardwood splitter to size, sand one end to a point and glue it into the kerf with the point facing the blade (photo above).

		Sources for some of the hardware and supplies mentioned in this tip. Freud Rip Blade Model LM74R010 222250

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From the Woodsmith Shop TV Show: Make this quick mount for a Machinist’s Vise on your Workbench

Even though removing dried glue squeeze-out is a common task, it’s no picnic. But, as you can see in the photos above, a chisel is the perfect tool for the task.

When glue has dried in a corner, like the drawer you see above left, try a bevel-down grip to “pop” the glue out. The bevel acts as a “safety” to keep the cutting edge from gouging the workpiece.

Squeeze-out on edge joints calls for a different approach. Here, you want to hold the chisel nearly vertical and pull it along the glue line (inset photo). This scraping action quickly shears off dried glue.

One more thing: To avoid having to spend a lot of time resharpening my best chisels, I bought an extra, inexpensive chisel just for this job.

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From the Woodsmith Shop TV Show: Here’s how to hide the shelf pins in your next shelving project (See information on a straight plunge router bit).

		Sources for some of the hardware and supplies mentioned in this tip. Amana ¼” Straight Plunge Router Bit, Model 45211 271626

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From the Woodsmith Shop TV Show: Build this Lumber Rack from a single sheet of Plywood.(download lumber rack plans)

But there are a couple ways to avoid this. On a wide workpiece you can plane toward the center by working from both edges. And for a narrow workpiece, you can clamp a backer board for support. This way, the edge of the workpiece can’t chipout as you complete the pass with your block plane. (See information on block planes)

Coming and Going. To avoid tearout when chamfering end grain, plane toward the center of the workpiece from both edges.		Backer Board. A scrap board clamped against the edge of a narrow workpiece helps prevent tearout.

		Sources for some of the hardware and supplies mentioned in this tip. Robert Larson Block Plane, Model 895-2000 321321

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From the Woodsmith Shop TV Show: Often overlooked, a simple bench hook can save time and increase accuracy.