Bridger wrote:

Maybe make a circle cutting jig for the TS and cut half circles with it.
That could work, maybe. Fiddly. Not impossible.

circle jigs for the table saw are... OK... for large diameter circles.
trying to cut a small diameter stopped half circle that way sounds
dangerous to me.

That's what I did. It smoked and made lots of rude noise and got burnt crap
all over my brand new blade, but it fits.

Well, after I cut it in half and glued it back together, to shorten it by
5/32". Not sure there that error came from. I measured everything with a
dial caliper and laid out a test drawing with a precision compass before I
cut anything.

So now I have a piece of 3/4" plywood that pretty much just fits into the
opening, and I need to create a rim on the thing to get it fitted down.

I spent five hours on it so far.

Since I don't own a dado set and I haven't moved a saw blade off of 90 in
years, I'm kinda thinking one of those $22 deals is not such a bad thing
after all. I'll have six hours in it, at least, by the time I get it
fitted.

The next one will go a little faster, since I have all the measurements and
the rounding over jig, but it's still a lot of effort for something that
should be simple and quick. I'm not sure if I ever want to cut circles on
the table saw again either. Maybe I should re-make that jig and clamp it
to my scroll saw table. But it takes sixteen hours and three days to cut
thick plywood with that little anemic thing, and breaks 374 blades along
the way. I don't like it much, you might say. Scroll saws are for people
who don't want to get anything cut in a hurry.

I don't want to make love to it, I just want to cut stuff with it.

but you don't want a corner on your zero clearance insert snagging
your board just as it's getting close to the blade.....

Bah. I used a saw with a rectangular insert for years, and this was *never*
a problem.

--
Michael McIntyre ---- Silvan
Linux fanatic, and certified Geek; registered Linux user #243621
http://www.geocities.com/Paris/Rue/5407/