The shaper cutter was just not working out. The biggest issue was that is was just not big enough in diameter and therefore it wouldn’t go deep enough into the box side. So I checked things out with the dado blade in the SawStop. That worked 99% perfectly. I wish I’d have stuck with plan A to start with. The only issue is that yes, the dado blade “bottoms out” on the box side once the cut gets deeper than the height of the teeth. I can manage by making one revolution on the blade height and making two passes. I’ll actually be making three passes so I can get a slightly wider hand-hold scallop.
Here’s the base of the jig. It just clamps to the table saw.
I use a removable 1” strip along the right fence in order to shift the sled side to side, giving me a bit wider hand hold.
I tried to leave some gap under the side fences to allow for the copious dust and wood chips that accumulate.
The jig cuts a nice 1/2” deep scallop, that’s one revolution on the height adjustment down from full height. I do have to make two passes, lowering the blade one revolution on the crank, in order to account for the size of the blade’s teeth.
One sled for short sides, one for long sides. Place the sides with the inside up and top down toward the sled’s fence.
I want to create a dust collection chute to collect the debris. I’ll work on that later.
-- "The difference between school and real life is that in real life the tests come first, and then the lessons" -- Robert Lang, ReadWatchDo.com