SawStop Zero Clearance Insert Routing Jigs
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A 3D-printed jig system for making a SawStop Zero Clearance Insert (ZCI) using template routing. Allows precise router-
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A jig system for reproducing the SAWSTOP PCS throat plate.
The key idea is to use 3D-printed jigs to control the Yand Z axes, while the shape of the router bit defines the X-axis cutting profile, enabling a 3D template-based machining process to reproduce the curved slot of the PCS throat plate. The curved slot is not strictly necessary. If the material you are using has sufficient strength, you can directly make a constant-depth slot version instead.
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If you want to machine the full spindle arc clearance, download all files.
If you prefer a simplified depth-based slot, you can exclude files prefixed with "ASS".
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This video shows the full build process, including multiple iterations.
You can navigate the sections using the chapter markers in the description.
Update: April 7, 2026 — Added base STEP files required for non-Makita trim router users.