On the first one of these I made, I cut the slot at the rear (for holding the tail) on the band saw. But that was because I didn’t have a table saw that I liked to use. So, I decided to try the slot on the table saw.
The tail and all wing pieces will be out of 1/4” thick material. I have a Freud thin kerf blade installed, which cuts about a 3/32” wide kerf, and didn’t want to bother installing my dado blade.
Two passes of the thin kerf is less than 1/4”. I set the blade to cut 1-5/8” deep and using a scrap piece, set the fence so that 2 passes, with opposing sides riding against the fence, would leave a cut slightly less than 1/4”. Doing this will center the cut in the body. I ended up having to make a third cut on each piece to get rid of the little strip left in the middle.
This cut is a bit dangerous, I’ll admit. My blade has hardly any time on it so cut well. I held the piece above the fence and rode my left hand along the fence with my fingers hanging out over the edge of the fence, with my thought being that if I kept pressure on my palm on the fence that it’d keep my fingers out of the blade. I used a push stick with my right hand on the bottom, outside of the piece to push it along.
I can’t recommend this cut but it worked for me. If I make more of these in the future I will take the time to make some sort of sled for this purpose.
-- Randy Morter, Phoenix, AZ