The saw blade you have has teeth ground to what is called Alternate Top Bevel,
which leaves the distinctive kerf bottom you see. This is common for general
purpose, crosscut blades. Only rip blades have teeth ground flat-topped, and rip
blades are no good for cross-cutting, especially for the burrs you are trying to
make. A blade with an ATB+R grind has a combination of the ATB teeth and the
flat teeth, and could be what you are looking for. A well sharpened blade will
leave a nearly flat bottomed kerf, but the little wings at the outside edges of
the cut will probably still be noticeable. Since you are making burr puzzles,
I'll assume you are really cutting wider grooves, using multiple cut of the saw
blade. For this application, you really want a good dado set to get a wide, flat
Have you seen http://www.johnrausch.com/PuzzlingWorld/chap23.htm
where woodworking for making burr puzzles is discussed in detail?
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