Howdy,
What is the best way to cut 1.5″dado’s in an already set vertical 4 x 4″? Skill Saw, router…? I am a true newby to the craft and am trying to do a fence by myself after watching hired craftsman for 2 years on my remodel. Thanks to all who may reply.
Greg Partridge
Replies
Greg,
A few questions:
The dado is 1.5 wide, I'm presuming, by how deep and how long? Also will the dado be full length or will it be stopped at the top or bottom and will the ends have to be squared up? Is it supposed to be one long dado or will they be more like pockets?
The post is already in the ground and absolutely can't be removed to be worked on?
Will you be cutting just one dado or many of them?
What type of wood are the posts made of and is the wood clear and straight grained or is it rough and full of knots?
If you decide to work on the post in place, how long a run will you have to make with an extension cord?
Do you own a table saw or a router and, if you do, what make and model are they?
John White
----PLEASE KEEP CONFIDENTIAL THE 2 INQUIRIES AT END OF REPLY----Hey john,Unfortunately posts are well-set, in other words not going through a table saw.Run for cord is at max 40'18 Dado's to be cut @ depth of 1"Doug Fur, 4x4I have small (home depot quality) craftsman table saw and a midsize porter-cable plunge router.W/out being too demanding of your valuable time I have two other unrelated questions: 1. In process of remodeling we moved a wall to increase the size of our woodshop. It is now large enough for a shop size table-saw. In your opinion what is the best table-saw? bang for buck AND w/out cost consideration. 2. We are commisioning a dining room table. 12' x 4'. We will most likely have to bookmatch, but would prefer a solid, single peice of wood. Am I dreaming? Any imaginable way to get a slab in African Mohagany for those dimensions. (we will build in place). Buy a tree? Different hardwood? --PLEASE keep the above inquiries confidential (particularly #2)--.THANKSGreg Partridge
Greg,
First of all this is a public bulletin board, anyone subscribing to Fine Woodworking.com can read items posted here. If you want to keep something private you need to click the "Reply via e-mail" button at the bottom of the message box, then your message won't wind up on the public site. You can remove your questions about the table by clicking on the edit button at the bottom of your posting.
As to the dadoes, it will be a physically demanding job to cut the dadoes with the posts in place. What you will need to do is build a jig, nothing fancy, along the lines of a mortising jig for your router. If you search the FWW archives you will find a few articles on the subject. The jig will attach to the side of the post with screws or clamps and then you will use it to guide the router in cutting the dado. For the size router you have, I would use a 1/2" diameter bit and plan to cut the dado in three steps of increasing depth. Use a heavy duty 12 ga. extension cord to prevent a voltage drop that will overheat the router.
The hard part will be holding the router sideways. If you will be working on a ladder, this will add to the risks and difficulty of the job. Hearing, eye, and respiratory protection will be needed. Doing a test post clamped to a bench wouldn't be a bad idea before heading outdoors.
Hopefully the posts aren't untreated Douglas fir, it isn't a rot resistant wood.
If price is no object then you have a lot of choices when choosing a table saw. FWW just ran an article reviewing 10" cabinet style table saws, it would be a good place to start looking. In that type of saw, the uniquely designed Saw Stop machine is definitely worth considering, for both it's practical features and the safety system. Further up the price ladder you can look at the European machines such as Knapp, Felder, and Rojek among others.
Slabs of wood on the scale that you are considering, while rare and expensive, are still available. You need to locate a cabinetmaker who has experience in working with wood of that size, he or she will know where to find what you are looking for.
John W.
Edited 6/6/2006 4:06 pm ET by JohnWW
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