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I also cut a few extras pieces to help me to set up the
dado blades for the proper thickness. They also help me set the height
of the blade. It's important that the tops of my pieces are all flush! |
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I use the story pole to set up my table saw sled. The
pole tells me where each dado should be. Set the stop on the sled and your
work piece will come out in the same place. Remember there are two story
poles, and two groups of wood. Each group has a different spacing pattern,
so I do my best to keep them from getting mixed up! |
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My "Dubby"
table saw sled has it's own stop, but it's not wide enough to line
up all these pieces. Instead I clamp a "Speed Square" to the fence. I also
clamp the bundle to the fence, safety first! |
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I "ganged" the 20 shorter parts together in bundles of
five, and wrapped the end with tape to keep then flush with each other.
Then I cut the first dado in each bundle. |
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After the first dado is cut, I remove the tape and slip
a piece of stock in the dado (second bundle in the pic at left) then rewrap
with tape. |
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Out comes the story pole again to line up the second
dado, and then make that second cut in all these bundles. The little piece
of wood in the first dado keeps the stock rigid thru all the handling,
and when complete, all the dados will line up perfectly. There is little
room for error here. |
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I continue using the story pole and making more dados
until too much of my stock is hanging off the sled. It's time to turn things
around! |
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I flip the story pole end for end (as well as my bundles)
and continue marking and cutting. You'll notice in the pic at left that
the tape is on the other end now.
After I finish these bundles, I do the long pieces in
the same manor... |
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...until I have a pile of parts!
|
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The dry fit is perfect and square! For the glueup I use
a slow
set epoxy so any glue drips will blend in with the finish. When the
glue dries I sand any imperfections in height with my 5"
random orbit sander. |
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Finally I ease all the inside edges with a 1/8"
round over bit. Touch up sanding by hand, and then finish with a spray
poly in a can, sanding lightly between coats. |
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Rockler
Dovetail Jig Combo with Half Blind and Through Dovetail Jig Templates
|
 |
|
|
Back
to the drawer this grid fits into!
|
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