I made a new (router) dado jig this morning. My old one was made in
haste for a bookcase project. It worked fine, especially once I made it
(more easily) adjustable, but it's not long enough for a project I have
To adjust the dado width, I used threaded (female) inserts and star
knobs. The last time I used those inserts I had a devil of a time
getting them into the wood. Some people here suggested cutting the head
off a 1/4-20 bolt, chucking it into a drill, and threading a pair of
nuts onto it as a back stop.
That sounded like a good idea, and I was just about to cut the head off
a bolt when another idea struck me. I threaded the insert onto the knob
itself, all the way to the body of the knob. Then I turned the insert
into the wood by hand with the knob. When the knob touched the wood, I
backed the knob out of the insert.
To my surprise, it really was flush with the wood, but I turned it in
another half-turn with a screwdriver anyway. In retrospect, I could have
eliminated that step by putting a washer (one whose outer diameter was
smaller than the insert) onto the knob threads before putting on the
It's probably not a better method than the one suggested here if you're
doing a lot of them, but it worked fine.
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