Wooden Grate - How to do it

bottoms would need to be 'uniform'. Do you mean smooth? If so, that looks like a non-starter. But if you only mean with the same projection ... give what you've described a try ... it looks like you already know the answer.

Cut the dado 1/2 way through (or SLIGHTLY proud of 1/2 way) then turn the pieces 90 deg. and run them through again.

If appearance is critical, make a sled with a 3/4 runner on the top (as well as any on the bottom) spaced 3/4" away from the edge of the dado blade. Make the first cut against the runner and slip it over the runner for the rest.

Just my best guess and 2 cents worth.

Bill

Very straight forward process using a T/S, a sled, and a dado.

Get Fred Bingham's book, Practical Yacht Joinery.

He fully describes the process, complete with pics and sketches, for making teak cockpit grates for sailboats.

Lew

Cut the dados on wider boards first then rip the board into 3/4" strips. Less work, and you don't have to worry about tearout.

If you have a dado set for the TS set that's probably your best bet.

If you have a crosscut sled for your TS then you could cut spacer blocks that are 1.5". Set a stop on the sled, make a pass, add a block, make a pass...

-Leuf

Pretty simple with the router if you've got the ponies for a 3/4 bit and a table.

What he said, or a "locating finger" ala box joint jig, used in a similar manner on a sled or sacrificial miter gauge fence.

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