Wooden Grate - How to do it

[Hoosierpopi]

I want to make a wooden "grate." out od 3/4 stock. I want to cut dado's (?) 1/2-way through the 3/4" square stock (X" long) such that they intersect such that the "holes" formed are 3/4" square and the top an bottom surfaces of the assembled "grate" are uniform (relatively) surfaces.

I have a TS, Chop / Miter Saw and porter cable router(s).

I would like to find a jig such that I can index the cuts (as on a box joint jig - or some other lzy man's approach.

I am not building furniture!

Any links to plans for jig or how to article(s) would b appreciated.

[BillinDetroit]

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

[Lew Hodgett]

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

[Leuf]

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

[George]

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

the sliding dovetail section for ideas. I make grid trivets the same way you make a grid.

[B A R R Y]

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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