I don't know about the Bosch saw, but I have made inserts using plywood
or mdf for a Delta contractors saw. Use the old insert as a pattern.
First bandsaw out slightly larger and then use a router in a table with
a pattern following bit to cut to the exact size. You will probably
need to build a jig with hold down clamps to safely hold the patten
(old insert) and the one you are cutting together. Use small screws to
adjust the height. I presume the tabs you are talking about adjust the
height. Somewhere in this group I have seen someone post a message with
a link to a website with pictures.
Patt wrote:
>
> I have the Bosch 4000 t/s. If anyone has made a zero tolerance insert, how
> did you duplicate the little tabs on the under side, like the factory
> insert. What material did you use?
> Patt
They sell zero clearance inserts for that saw. Try
http://www.coastaltool.com that's where I got my ZC insert.
Pete C.