On Fri, 3 Jun 2005 08:52:16 -0400, "Buck Turgidson"
wrote:

Looking for suggestions on how to cut accurate dados [without] a dado blade.

IMHO, nibble them on the table saw, rather than using a router. This may
vary, depending on the stability and accuracy of your own kit.

You'll want a crosscut box that's nice and stable, then you just cut the
two side cheeks of the dado. Remove the central waste by either nibbling
at it, or with a rebate plane (a Stanley #92 is just the job) and maybe
a router plane (#71) to shift the bulk. If it's not too tough a timber,
then this short-grain stuff just flies out.

I wouldn't do it with a router. It's hard to get such neat straight
edges, and there's a real risk of an accidental divot in at least one
place. You also have to make the first cut on both sides of the bit, so
one side is climb milling.

If you rout it, make a good guide jig to control the router.

Personally I'd also use a cutter about 2/3rd of the dado width, and I'd
make one pass for each side. If you have the rigidity and the
confidence, then do it in one pass.

A router is obviously preferable if it's a bigger piece of timber than
you want to be sliding around on your saw's table.

--
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