Uploaded October 2025 | Updated September 2026, 1 week ago
Tired of tear-out, chip-out, and small pieces getting stuck in your table saw? In this video, I’ll show you how to make a zero clearance insert plate for the Evolution R255TBL table saw — it’s super simple, quick, and can be made in under 20 minutes using the existing metal plate as a template.
This upgrade makes a huge difference in your cut quality, especially when working with laminated chipboard or thin materials. It also improves safety by preventing offcuts from falling into the blade chamber — and the best part? It’s cheap, replaceable, and requires no special tools.
Watch step-by-step as I make this insert from start to finish, share all the dimensions, and show how to perfectly fit it to your Evolution saw. Whether you’re a hobbyist or professional woodworker, this is a must-do DIY mod for cleaner, safer cuts.
📏 Project highlights:
Uses your existing metal plate as a template
Takes less than 20 minutes to make
Boosts cut precision and safety
Easy to replace or make more in the future
Works perfectly on the Evolution R255TBL
If you found this project helpful, don’t forget to like, comment, and subscribe for more woodworking, DIY, and tool review videos!
My other videos on Evolution Table Saw:
- Simple Fix, Perfect Cuts! Zero Clearance Insert for Evolution Table Saw - youtu.be/Nr1m2SvzeXs
- I Have a Problem with My Table Saw R255TBLX… Here’s How I Fixed It - youtu.be/8MDPc_G5Uzs
Trend Digital Depth Gauge on Amazon:
UK - amzn.to/3WdyKkl
USA - amzn.to/4o5WnHh
Shopping for Evolution tools - USE MY DISCOUNT CODE AT CHECKOUT - CASUAL for 10% OFF. This works for all tools from Evolution!
UK
- Table saw R255TBLX+ - shop.evolutionpowertools.com/collections/table-saw/products/evolution-r255tbl-next-gen-jobsite-table-saw-with-28t-multi-material-blade?variant=40786010865700
- Table saw R255TBLX - shop.evolutionpowertools.com/collections/table-saw/products/evolution-r255tbl-portable-jobsite-table-saw?variant=41085945184292
USA
- Table saw R10TBLX - store.evolutionpowertools.com/collections/table-saws/products/r10tblx
PL
- Table saw R255TBLX+ - sklep.evolutionpowertools.com/collections/pily-stolowe/products/przenosna-pilarka-stolowa-evolution-r255tbl-1
All my tools, woodworking accessories and video making kit is now in one place for you to check out. These are Amazon affiliate links. With a purchase through this link, you get an awesome tool and you will support my channel without spending a penny more. As an Amazon Associate I earn from qualifying purchases, thank you for your support!
Link to Amazon is just below! Thanks!
Tools I use and recommend:
amazon.co.uk/shop/casualdiy
Shop on Banggood - banggood.com/custlink/DmKdnShFdO
You can now support my channel via Patreon. If you feel my content adds value for you or its entertaining then help me continue to do so.
Any donations via Patreon are so much appreciated, you can find out more here: patreon.com/casualdiy Thanks!
You can support my channel by dropping some change in the Casual DIY Tip Box. Thanks for your support!
paypal.me/TomaszFranczyk
You can find me on:
Instagram - instagram.com/casualdiy
Twitter - twitter.com/CasualDIY
Facebook - facebook.com/CasualDIY
Etsy - etsy.com/uk/shop/CasualDesignTF
Web page - casualdiy.com
Email - casualdiyuk@gmail.com
#ZeroClearanceInsert #TableSawUpgrade #EvolutionTools
DISCLAIMER
My videos are for entertaining purposes only, your safety is your responsibility. Please do not follow my actions if you find them unsafe.
Tired of tear-out, chip-out, and small pieces getting stuck in your table saw? In this video, I’ll show you how to make a zero clearance insert plate for the Evolution R255TBL table saw — it’s super simple, quick, and can be made in under 20 minutes using the existing metal plate as a template.
This upgrade makes a huge difference in your cut quality, especially when working with laminated chipboard or thin materials. It also improves safety by preventing offcuts from falling into the blade chamber — and the best part? It’s cheap, replaceable, and requires no special tools.
Watch step-by-step as I make this insert from start to finish, share all the dimensions, and show how to perfectly fit it to your Evolution saw. Whether you’re a hobbyist or professional woodworker, this is a must-do DIY mod for cleaner, safer cuts.
📏 Project highlights:
Uses your existing metal plate as a template
Takes less than 20 minutes to make
Boosts cut precision and safety
Easy to replace or make more in the future
Works perfectly on the Evolution R255TBL
If you found this project helpful, don’t forget to like, comment, and subscribe for more woodworking, DIY, and tool review videos!
My other videos on Evolution Table Saw:
- Simple Fix, Perfect Cuts! Zero Clearance Insert for Evolution Table Saw - youtu.be/Nr1m2SvzeXs
- I Have a Problem with My Table Saw R255TBLX… Here’s How I Fixed It - youtu.be/8MDPc_G5Uzs
Trend Digital Depth Gauge on Amazon:
UK - amzn.to/3WdyKkl
USA - amzn.to/4o5WnHh
Shopping for Evolution tools - USE MY DISCOUNT CODE AT CHECKOUT - CASUAL for 10% OFF. This works for all tools from Evolution!
UK
- Table saw R255TBLX+ - shop.evolutionpowertools.com/collections/table-saw/products/evolution-r255tbl-next-gen-jobsite-table-saw-with-28t-multi-material-blade?variant=40786010865700
- Table saw R255TBLX - shop.evolutionpowertools.com/collections/table-saw/products/evolution-r255tbl-portable-jobsite-table-saw?variant=41085945184292
USA
- Table saw R10TBLX - store.evolutionpowertools.com/collections/table-saws/products/r10tblx
PL
- Table saw R255TBLX+ - sklep.evolutionpowertools.com/collections/pily-stolowe/products/przenosna-pilarka-stolowa-evolution-r255tbl-1
All my tools, woodworking accessories and video making kit is now in one place for you to check out. These are Amazon affiliate links. With a purchase through this link, you get an awesome tool and you will support my channel without spending a penny more. As an Amazon Associate I earn from qualifying purchases, thank you for your support!
Link to Amazon is just below! Thanks!
Tools I use and recommend:
amazon.co.uk/shop/casualdiy
Shop on Banggood - banggood.com/custlink/DmKdnShFdO
You can now support my channel via Patreon. If you feel my content adds value for you or its entertaining then help me continue to do so.
Any donations via Patreon are so much appreciated, you can find out more here: patreon.com/casualdiy Thanks!
You can support my channel by dropping some change in the Casual DIY Tip Box. Thanks for your support!
paypal.me/TomaszFranczyk
You can find me on:
Instagram - instagram.com/casualdiy
Twitter - twitter.com/CasualDIY
Facebook - facebook.com/CasualDIY
Etsy - etsy.com/uk/shop/CasualDesignTF
Web page - casualdiy.com
Email - casualdiyuk@gmail.com
#ZeroClearanceInsert #TableSawUpgrade #EvolutionTools
DISCLAIMER
My videos are for entertaining purposes only, your safety is your responsibility. Please do not follow my actions if you find them unsafe.
