Zero‑Tolerance Insert for Evolution R255TBL / R255TBL+ / R255TBLX /R255TBLX+

This is a custom zero‑tolerance insert designed to insert into the original throat plate of the Evolution R255TBL / R255TBL+ / R255TBLX /R255TBLX+ table saw. The stock insert has a wide opening that causes tear‑out, chip‑out, and small offcuts falling into the blade cavity. This model solves all of that.

I designed this insert to fit perfectly into the original metal base plate, with tight tolerances and a clean, flush surface. It provides:

• cleaner cuts

• better support for thin material

• reduced tear‑out

• improved safety

• a more stable work surface

This insert has been tested on the R255TBL+ and fits the original plate without modification.

Features

• Zero‑tolerance slot for minimal tear‑out

• Exact fit for the Evolution R255TBL series throat plate

• Flat, rigid top surface for stable cutting

• Optimized thickness to match the factory insert

• Works with the standard riving knife

• Printable in PETG, ABS, ASA, or Nylon (I used PETG)

Printing Recommendations

• Material: PETG or ABS recommended

• Layer height: 0.2 mm

• Infill: 100%

• Perimeters: 3

• Print orientation: flat, with the top surface facing up

• No supports needed

Installation instructions

1 Prepare the Saw Safely

Safety First

Ensure the saw cannot start accidentally during installation.

• Unplug the saw completely

• Lower the blade to its minimum height

• Remove the riving knife for this step

• Clean the throat plate area

2 Attach the Insert to the Metal Plate

Secure the printed insert so it cannot shift during the cut-through.

• Place the printed insert underneath the metal throat plate

• Use strong double‑sided tape to hold it in place

• Ensure it sits flush and centered

3 Position the Plate on the Saw

Install the plate so the blade can cut the zero‑tolerance slot.

• Put the metal plate (with insert attached) back into the saw

• Verify the blade is still at its lowest position

• Make sure everything is seated correctly

4 Create the Zero‑Tolerance Slot

Recommended

Cut the perfect slot by raising the blade through the insert.

• Place a piece of scrap wood over the slot area

• Clamp it down to prevent tear‑out

• Plug in the saw and turn it on

• Slowly raise the blade through the insert until fully up

• Turn off the saw and unplug it again before touching anything

5 Remove the Backside Material

Clear the remaining plastic so the riving knife fits properly.

• Remove the throat plate from the saw

• You will see a small piece of plastic behind the blade cut

• Remove this piece with a handsaw or flush‑cut saw

• Reinstall the riving knife and verify clearance

6 Final Check and Installation

Ensure everything fits and moves freely before use.

• Reinstall the throat plate

• Raise and lower the blade to check for rubbing

• Confirm the riving knife fits without resistance

• Your zero‑tolerance insert is now ready for use