Zero clearance block for Metabo TK 1685/1688 table saw

This model is a zero clearance block for the fence of the sliding table of the Metabo TK1685/88 table saw. It aims to reduce tearout on crosscuts as it supports the material at the end of the cut.

Below an example of a cut in spruce first without and then with the zero clearance block. As spruce is very soft this is an extreme example.

The distance between the end of the fence and the saw blade might differ between individual saws. The 3mf file included works for my saw. It covers a maximal distance of 5.5mm. Print the part with a thick solid bottom so you can cut it flush with the saw blade after installation and still leave solid material.

If the 5.5mm are not enough you can also edit the FreeCad file which is included. You have to adapt the field "Breite Splitterschutz" in the spreadsheet

Print parameters:

I used the 0.2 structural profile in PrusaSlicer for core one as a basis. The most important parameters are: 

• Rotate the part such that the outer side facing the saw blade faces down (it's the only orientation where printing without supports is possible)

• 0.4 mm nozzle, 0.2mm layer height

• 2mm solid bottom shell (necessary so you can cut it flush with your saw blade)

• 4 perimeters minimum (for strength)

• 30% infill (for strength)

• I would not use PLA but e.g. PETG because it has a higher impact strength.

Additionally needed parts:

• m6 x 12mm bolt

• m6 nut

• m6 washer

See image below for assembly.

For the first cut crank the blade up sufficiently high to cut the block flush on it's full height.

Use this at your own risk. I take no responsibility for injuries or undesired outcomes resulting from the use of your printed version of this model. I also don't guarantee that it will reduce tearout in your use case.