I needed some shelves in my office area, and wanted to challenge myself to come up with a super simple yet still strong design using random scraps. They’re basically 2×2 chunks with a dado cut to accept a bit of plywood. They’ve actually got the potential to not be very ugly, but I call these ones ugly for sure on account of the smudged paint, uneven bracket sizes and scrap planks thrown on top :)
I used a stack of 3 circular saw blades as my dado set. The blades alone will cut a .210” slot. The plywood was about .330” thick and so I used an assortment of plastic shims between the blades to find an exact fit. Matthias Wandel over at Woodgears.ca had a great article on this method. My tablesaw wasn’t built to take a dado set, as it is a compact model and has a short arbor, but this method of cutting dadoes works great for me. The main trick is to get saw blades that match exactly in diameter, have the same tooth spacing, and stagger the positions of the teeth so that the waste doesn’t bind up in the stack.
I liked that this process could be scaled up easily and didn’t take very long at all (under 2 hours start to finish). Do you guys have suggestions on other simple, functional builds? Please share!
Thanks for looking!
-- Jesse --