I need to make five dados of 1 1/8 inch each. My adjustable dado blade only goes to 13/16, so I have to make two passes. Through trial and error (second try, actually) I created a perfectly snug fit. I want to use that as a template for the five cuts.
Now, how do I duplicate it?
I'm using a radial saw and cheap pine 1x4s. Waste isn't really an issue. I guess I could trial-and error all five and toss those that aren't snug, but I'd rather find some more spohisticated technique.
For instance, I'm considering this:
- Place the template against the fence.
- Place the 1x4 against the template, lining up to where I want the dado.
- Using mending plate and small screws, fasten the two pieces together. This is not fine furniture, so the screw holes don't matter.
- Align the dado blade with one side of the template dado, pass throught the template and cut the 1x4. Take care to not shave anything off the template.
- Slide the template so the other side is against the blade and repeat.
- I should have a new dado exactly the size of the template. Repeat for all five cuts.
Any flaws in this? Any better ideas?