Replies

1. 
   geedubbee | Jun 04, 2020 11:43am | #1

   Large stock removal is an area where a dado stack shines. I would try a different approach; cut tongues on your shelves and smaller dados on your sides. If the dados are a decorative element then this would not help you, a dado stack will.

   
2. 
   toolanddie | Jun 04, 2020 11:56am | #2

   Thanks for your reply. My shelves are a little different, most of the sides will be exposed. I have to cut 1-1/2" wide notches by 3/4" deep, on the 2"x 2"legs. Do you think it would be better to use a 1-1/2" router bit and make small passes or try to get a 1-1/2 dado blade? I am uploading some pics to help you better understand what I'm trying to do. I completed the rack, but damaged a lot of wood using a 3/4" router bit. I'm taking it apart to change the legs to walnut, like the shelves. Thanks again

   
3. 
   salamanderseth | Jun 04, 2020 12:39pm | #3

   It sounds like you want to do this in one pass. I would use a dado stack, but not attempt it in one pass. It will go faster than the router for sure, but, whats the rush? may take an extra ten mins...take the time and be safe.

4. 
   john_c2 | Jun 04, 2020 01:18pm | #4

   Now that I've seen pictures, it's more clear. Doing all of those dad is with a router is nuts. Dado stack is the way to go. But I've never heard of a dado stack 1-1/2 inches wide. Not sure it exists. My arbor barely fits 3/4. Some are a little longer, but not by much.

   But it isnt a big deal. Set a stop block, make cuts in all the legs, reset the stop block, finish the cuts.

   The only drawback to a dado stack is imperfections in the dado bottoms, which might be seen in your design. You could use a chisel to clean up, or finish the dado bottoms smooth with a light router pass.

5. 
   _mj_ | Jun 04, 2020 02:57pm | #5

   Definitely go dado stack. If you make a sled for the project you can put a stop block on either side and get consistant results. With the two stop blocks you can first remove the waste and then use the speed tenon technique to get rid of the score lines from the outer blades.

6. 
   geedubbee | Jun 05, 2020 04:18pm | #6

   I can only agree after seeing the pics. Moving those pieces via a sled across a dado stack is exactly how I would do that.

7. 
   mdorsam | Jun 06, 2020 10:39am | #7

   I'll offer another approach... just to have an alternative...
   Mark the width and depth of the dado, takeout the majority of this on the bandsaw using several cuts (then chip-out the majority of this with a screwdriver), then finish and fine-tune the cut on the router table. This procedure makes short-work of clearing the bulk of the material, safely and with less stress than tablesaw dado cuts; at the router table use stop blocks to yield a consistent cut with clean edges and flat bottoms. I have a sliding table saw, so I don't like to change-out blades for dado cutters; the bandsaw and router table approach is quite effective.
   Another approach is to use a router-plane (Lee Valley, Lie-Nielsen) to clean-up the rough bottoms left by dado blades, and ensure a consistent depth.
   Regarding any approach, it's easy to recommend taking the extra time for several passes, relying on stop-blocks and sleds - in this manner, establishing a process that will yield the desired results.

8. 
   toolanddie | Jun 17, 2020 08:22am | #8

   Thank you guys for all the good advice and amazing input on different ways to tackle the problem. I now have a much better ideas. The dado seems to be the way to go, the router took forever. I like mdorsam's idea, with the band saw and router combination too. I just have to be a little more patient, whichever method I go with it's going to be in small bites. Thank all you guys again for being so amazing and helpful.

9. 
   mikaol | Aug 24, 2020 10:09am | #9

   I have an 1-1/2" router bit but bit-size isn't important if you're in a hurry. Regardless of which you choose, dado or router, woodworking's supposed to be fun and most fun comes from doing what's less frustrating. Play. Waste some scrap on different methods. You'll figure it out.
   Mikaol