Cut Big-Time Joints with a Small-Time Saw

 

Photo A

After trimming the jig to size, the right
edge indicates precisely where your
blade will cut. Slide the edge up to
your left outside cut line.

 

Photo B

The saw kerf should remove the left
outside cut line. Allow for the blade
width when sawing at the right
outside cut line.

 

Photo C

Slide the jig along as you saw away
waste to keep cuts at a uniform depth
and provide a stable surface for your
saw.

Waste removal

If you have multiple workpieces to be dadoed the same, clamp them together for uniform cuts and a stable surface to support the guide. Mark where the dado will start, then use the mating workpiece to mark the end of the cut.

Next, adjust the saw blade to cut the dado depth plus 1/2" (the thickness of the guide base). Here we're cutting a dado as deep as the mating workpiece thickness. Test cut a scrap piece to confirm the depth.

To begin cutting the dado, slide the guide edge to the left-hand mark [Photo A]. (Clamp the jig to the workpieces, if necessary.) Place the saw base against the fence and make your first outside cut. Then slide the guide toward the other cut line until the right jig base edge is a blade-width distance from the right-hand mark, and make the second outside cut [Photo B].

With the joint defined, now cut kerfs roughly every 1/8" to 1/4" apart between the outside kerfs [Photo C]. You can make the kerfs slightly farther apart for softwoods, such as this cedar, or closer for hardwoods, such as white oak.