Zero Clearence Table Covers

In the last post we covered table inserts, some scroll saws don't use inserts, they simply have a hole in the table. For these types of saws you can use a cover on your table to accomplish the same thing, more support underneath and less space around the blade.

Some users simply trace the outline of their table onto a piece of hardboard, cut it out and clamp it to the table top, the problem with this method is that the clamps always are getting in your way.

What I recommend is to trace out your tables shape leaving about 1" more around the edge onto the hardboard, plywood, MDF or the material that you have chosen, and add cleats to the bottom side. The cleats will hold the cover from moving around, and if you wish, you can now clamp to the edge of the table with small 1" - 1-1/2" c-clamps, leaving the top free to move your cutting uninterrupted.

To get started, choose your material, outline your table top as above, now center your cover on the saw. To make the cleats cut some 3/4" wide pieces out of 3/4" thick stock, pine will do. Then cut them into about 1" in lengths and glue the cleats in place using clamps so that they are snug to the edges of the table. When the glue has dried mark the hole for the table from below and drill an appropriately sized hole for your blades. Now your cover is ready to use.

There is one other benefit to using this method, some saws have really small tables, especially the round type. By increasing the thickness of the cover from 1/8" to 1/2" - 3/4" you can make the tables size and shape to fit your preferences. The only time this could pose a problem is if you are cutting really thick stock, then just remove the cover to get back the total capacity of your saw.