Bosch REAXX Table Saw - Make Your Own Zero Clearance Insert
The Bosch REAXX jobsite table saw is a wonderful tool, but Bosch zero clearance table inserts (throat plates) are expensive. The Bosch TS1006 Table Saw Zero Clearance or Dado Insert has a list price of $60, and discounts are minimal. Due to litigation with SawStop, Bosch REAXX saws are not currently available for purchase in the US, but they are available elsewhere in the world, and many people in the US own one, including me. A nearly identical zero clearance insert for the nearly identical Bosch 4100-09 table saw costs $6.10 at the big box store. Why does the zero clearance insert for my Bosch REAXX table saw cost nearly $60?
If you don't own a Bosch REAXX saw, stop here. If you want to keep reading, I will share my experience making a zero clearance insert for my Bosch REAXX table saw.
If You Want to Use a Dado Set with Your Bosch REAXX, You Need to Buy an Official $60 Bosch Zero Clearance Insert.
That is because you need a special screw that lets you attach dados that are wider than 1/2 inch to your Bosch REAXX table saw. The only way to get that special screw is to buy the Bosch TS1006 zero clearance insert. The Bosch TS1006 comes in two parts - the zero clearance insert, and that special screw. The special screw goes INSIDE a threaded hole at the end of the arbor, and has a sleeve that holds the wider dado blades in place. See your REAXX user manual for additional details.
If you use multiple blades or different dado widths on your REAXX table saw, then you will probably want a zero clearance insert for each blade and each dado width that you use. When a zero clearance insert is tight against the blade on both sides, then small parts cannot get between the blade and the table insert and jam things up or trigger a kickback.
I spent a lot of time thinking about how the table insert on the REAXX saw is held down on the table saw. There are two tabs on the upper end of the insert. Those tabs slip into matching slots in the saw. On the bottom end of the insert is a rounded, sloped cutout. A rotating cam locks the insert in its place. The question was, "How to duplicate Bosch's zero clearance insert with a homemade insert?"
After several months of studying the problem (NOT full time!) I noticed the small screw holes in the tabs that support the insert. I tested them and they are metric size M4 threads. You can drill and countersink screws to hold a homemade insert in place. That is the answer I have been looking for!
Last edited by Tool Agnostic; 03-10-2018 at 06:30 PM.