Make a zero clearance table saw insert that is both accurate and cheap.

Step 1: Stock

Start with a flat piece of hardwood. I chose maple.

Step 2: Width

Cut the stock to the exact width of the insert opening.

Step 3: Compass

Use a compass to find the arc of the insert opening and trace it onto the wood.

Step 4: Sand

Shape the wood with a disc sander. Fine tune the edge with a sanding block to get a snug fit.

Step 5: Jointer

If the stock rises above the surface of the table, remove some wood so that it lies just below the surface of the table.

Step 6: Tap

Drill holes in the four corners of the insert corresponding to the hold shelves on the inside of the insert opening. Tap the holes and insert headless hex screws. Adjust the screws so that the insert lies flush with the table top.

Step 7: Cut

The 10" blade on my table saw did not lower enough to to allow the insert to be completely inserted so I attached a 7 1/4" blade. Make sure the kerf is the same as the 10" blade. With the insert in place, turn on the motor and slowly raise the blade, cutting a slot for the blade.