Slightly new twist on fitting to dadoes?
I needed to make a set of louvers to install in a gable end as a vent the other night and needed to get it done quickly. I got the idea to use my dado set for the grooves but setting them to the exact width of the boards can take a lot of time that I didn't want to spend. So I came up with the idea to just set the stack for some random width less than the total thickness of my boards and then rabbet the ends of the boards to fit. The boards were about 3/4 thick (never bothered measuring) so I put together a stack about 1/2" thick (also didn't bother measuring).
I decided that 60* would be an reasonable angle for the slats so that way I could use the fence to set the distance from the ends of the uprights for each slat and the miter gauge for the angles. Since each side has to be the mirror image of the other by picking an easy angle on the gauge I could flip the miter gauge back and forth from left to right for each side without moving the fence and without an angular error.
Once the dadoes were done I took the slats and stood them on end against the table saw fence and nibbled away at the first slat doing one side and then flipping it around and cutting the other side. After about 3 or 4 nudges of the fence closer to the blade and I had the fit right so I milled all the ends that way.
Because I used the dado stack to cut both the dadoes and the rabbets the depth of the grooves was the same as the width of the rabbets so that issue took care of itself. From concept to finished product took less than two hours with a set of glued and brad nailed louvers.
I found this way to be much, much faster than trying to fit the full sized board ends to a full sized dado.
Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
Last edited by Cherryville Chuck; 06-24-2016 at 11:30 PM.