Making an Insert for the Porter Cable Scroll Saw

As a follow up on my review of the Porter Cable Scroll saw I make a wooden insert to replace the flimsy plastic one that came with the saw. This will fix the only thing that I really didn't like about this saw.
/ rickmayotte
www.rickmayotte.com

[@johnsaniga1269]

I just started using this saw and was aggravated at two things; changing out blades and the plastic insert. I was considering making some sort of replacement insert and this video is spot-on what I needed. Much appreciated!

[@robertlinton5966]

Simple, elegant, thanks bud! You are a fine fella

[@deanroadifer6013]

I just got my new Porter Cable scroll saw today and it only took about 5 minutes to decide I needed an insert for the saw. I used White Oak about 1/2" thick drilled a very small hole in the center to mount it between centers on the lathe then turned the the the piece round till it would fit snugly then measure how thick the rim would be then turned the lower end down to the diameter of the lower hole. At this point I discovered that the holes in the table are a slight oval shape instead of round. I used this to my advantage and just sanded the narrow sides down till it would fit snugly in the hole. Since the piece is oval it will not rotate. Then all I had to to was drill the hole for the blade. I made sure to leave the top section just a little thicker than needed then after I had a good fit I ran the insert through my thickness sander taking off just a little with each pass till I had it flush.

[@tomx63]

Rick, Great video for creating an insert. To line up those separate pieces you can mark and drill the center from the compass point. Then when you're ready to attach them, align them using the same drill bit used to drill out the centers. I know the blade is off-center, but it's close enough when it's time widen the alignment hole for the blade. I've made a few inserts for this saw using a router table. Having the sturdier insert was a HUGE improvement to this saw. If you're working with thin material and cutting anything intricate the sturdy insert is a must have.

[@XMAWally]

I have the same saw and I have trouble with the thumb screws that hold the blade. The bottom one tends to force the blade out of the slot because the twisting of it pushes it out.

[@BluegrassBushcraft]

Been planning on doing this myself but wasn't sure where to start. Now you got that covered.
Just for thought. Instead of soda box for a gasket try something more like a milk jug. More durable and could probably superglue it to the inserts.
Great video and Thanks for sharing.
God bless.

[@kentharris7427]

Thank you for the video. Going to purchase the Porter Cable Scroll Saw today. I'm going to make the disk out of aluminum and make it on a CNC router.

[@tims6376]

I made a one piece insert from scrap bamboo flooring and one from a scrap piece of oak when I cut them I included the nub that keeps it from spinning it turned out perfect no gaps but the other problem is the slow start motor I want to add a foot pedal but I don't know how it will work with the delay in the motor.

[@hassanal-mosawi6049]

thanks for sharing that

[@johnfitzgerald4274]

Thank you.

[@hughgriffiths5837]

Out of curiosity, can you use the table angle with this design? I assume the “L” shape of the cut out allows for the blade travel when angling the table of the saw. Just wasn’t certain. Thanks for the info on the design. Looks like it’ll work beautifully.

[@RickMayotte]

I haven't tried because I don't really use the angle feature of the saw but the slot could easily be changed to work with it if needed.

[@celenabutler1]

would you sell an insert that you have made to replace the plastic one it came with?

[@curious2308]

I have a question? will you be willing to make one of those disc and sell it. i would really love it if u made me one and of course pay you for it.

[@mackeymorgan4617]

Just curious, if the chief issue with the plastic insert was vibration, would a coat of urethane on the plastic insert snug it up enough to prevent vibration?

[@RickMayotte]

Hi Mackey, It wasn't that the insert was loose, the problem was that the plastic it was made from was too thin. If you were cutting near the edge of a piece it wasn't supported by the table, only the insert and it would bounce up and down because the thin plastic offered no real support. The wooden insert is very solid and solved this problem.

[@mackeymorgan4617]

@@RickMayotte Oh, I understand, now. The flimsy plastic piece wouldn't offer adequate work piece support, especially for small pieces. Thanks!

[@HighTone45]

That portercable is flimsy I hear