I made a miter saw ZCI yesterday. Something I have been meaning to do for a while. I had the piece of
true 1/4" ply laying around just for this purpose and I finally decided to make it.
My SCMS is the DeWalt DW-708. I've had it about 8 years now I think.
The stock Kerf Plate (p/n 395672-00) as DeWalt calls it is a two piece design. They are currently priced
at $4.30 each and you need two for a complete setup if you want to replace with the stock parts.
I removed the stock kerf plates and measured the depth of the recess, it was 0.256" so just slightly over
1/4". The width was 3" and the length I didn't measure just cut my blanks to match the length of the stock
I ripped two pieces of plywood just over 3" wide so I could use a hand plane to fit them after shaping. The
stock kerf plates taper a bit at the ends. There are also three counter-bored holes for mounting screws and
on the underside there are the ends of two screws that need a clearance hole drilled in the underside so the
ZCI will lay flat.
I used the stock kerf plates and traced the edge profile onto my blank. I then used a combination of block plane
and disc sander to shape to fit snugly. When I had the required shape I laid the ZCI in the slot but because of
the two screws that protrude up from below it would not sit flat. The next step was to lightly tap the top of the
ZCI over the location of each of these screws to leave a mark on the underside of the ZCI. I used this mark to
locate where to drill into the underside a clearance hole slightly larger in diameter than the screws.
For the mounting holes I first drilled a 3/8" Ø counterbore using a brad point bit to the depth of the screw head,
then changed bits and drilled through the ZCI with a 3/16" Ø bit. The location of the holes was copied off the
stock kerf plates, no measurements were taken.
And here is the result. I have not made the second ZCI yet but I plan to and have it on hand to be used for any
angled cuts I may make. I find I rarely tilt the blade left or right on the miter saw. I will usually perform those cuts
on the table saw or the RAS, depends on the application.
The photos are not the best, I grabbed some quick shots with my cell phone camera.