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3 Plenty-strong plywood joints

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2. Shouldered dado
Router on board
Enlarge Image
 
Make a simple right-angle T-square
from scrap and use it to guide your
router for cutting dadoes. Use the
channel in the arm to line up the
next dado.
Up close of router
Enlarge Image
 
Use a rabbeting bit to cut a precise
tongue length; change bearings for
different lengths. Adjust the bit's
cutting depth to control the fit of
the joint.
Crack in joint
Enlarge Image
 
For maximum strength, place the
tongue on the bottom of the insert
piece. This joint split when weight
was placed on it.

2. Shouldered dado

This joint matches a narrow dado with a tongue, created by cutting a rabbet on the insert workpiece. And when you use this joint at a corner -- where it shines best -- it becomes a lock-rabbet, providing more glue surface, greater strength, and superior rigidity to a standard rabbet joint.

Cutting a shouldered dado requires machining both mating pieces. First, cut the dado with your tablesaw's dado blade or a router with a straight or downcut spiral bit, as shown right. Next, cut the rabbet on the mating piece (center photo) so the tongue fits precisely in the dado. (Make cuts in test scrap to fine-tune the fit.)


Continued on page 4:  3. Splined butt

 

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Comments (1)
8166369528
lyndamike1209599 wrote:

Best is if the grain of the spline is oriented across the spline so it runs across the joint. Of course this means the spline will be of limited length so a number of pieces will be required if the joint is long. I've used a 1/8" x 3/4" metal bar for the spline with epoxy glue when I was concerned about the strength.

5/9/2014 12:33:55 AM Report Abuse

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