Cutting Tenons on the Dado Crosscut Sled

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Blog entry by Bob Simmons posted 11-15-2011 07:52 PM 7291 reads 7 times favorited 7 comments Add to Favorites Watch

Here’s a simple, quick, and safe way to cut tenons accurately. Most of the time when tenons are used in a woodworking project, there are multiple tenons needed. Whether you need a few tenons for a project or hundreds of tenons for production work, this method of cutting tenons works like a charm.

Read the complete articleCutting Tenons on a Dado Crosscut Sled

Read the complete articleLearn...How to Build a Dado Crosscut Sled

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-- Bob Simmons, Las Vegas, NV,

7 comments so far

View thebigvise's profile


191 posts in 2926 days

#1 posted 11-15-2011 08:09 PM

I’ve done them this way for years, with my shop-made dado crosscut jig. Ten years ago, I bought one of those 100-lb cast iron jigs like Norm uses for cutting tenons vertically, but I never took it out of the box. Finally, I sold it on e-bay.

-- Paul, Clinton, NC

View Joe Lyddon's profile

Joe Lyddon

10119 posts in 4077 days

#2 posted 11-15-2011 09:05 PM

Still in good form, Bob!

Very interesting…

I haven’t made a dedicated Dado crosscut sled yet…

I’ve been studying & thinking about one.

ShopNotes #99 page 24
Crosscut sled where the left bottom is adjustable to allow for whatever the blade width is;
it just slides up against the blade for any Dado width present.
Looks cool to me. Your sled is almost identical to it except for the Left side sliding to adjust to blade Kerf or Dado config. It’s always Zero Clearance.

COOL Videos as usual!

COOL method of cutting the tenons too… Makes good sense!

Thank you very much…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View Bob Simmons's profile

Bob Simmons

505 posts in 3039 days

#3 posted 11-15-2011 09:46 PM

Paul…I think you will agree that many woodworkers could save a lot of money by using a shop-made dado croosscut sled instead of purchasing an expensive tool to cut tenons. Glad to hear yours has worked out well for you these last 10 years.

Joe…You sure do study a lot ;)....When I need to adjust for a narrower slot, it is simply a matter of laying a scrap sheet of 1/4” ply or MDF over the surface of the sled. This as you know will serve for the zero clearance for the new dado cut. ....great to see you Joe.

-- Bob Simmons, Las Vegas, NV,

View Drew - Rock-n H Woodshop's profile

Drew - Rock-n H Woodshop

644 posts in 2716 days

#4 posted 11-15-2011 10:57 PM

Paul, I agree. I find tenons are a lot easier using dados. I guess it will get easier to use the tenoning jig if I use it more, bur for now I love the dado set for it. However, I cannot bear to part with my tenoning jig b/c I have found uses for it to make grooves for things standing on their top or bottom like a handle of a mallet I built to make a groove for a wedge driven into the top.
Click for details

-- Drew -- "I cut it twice and it's still too short!"- Rock-n H Woodshop - Moore, OK

View Maveric777's profile


2693 posts in 3102 days

#5 posted 11-16-2011 12:40 AM

Good to see you back at it Bob. Yet again informative stuff… I did build me a regular super sled but yet to build one for dado’s… Need to add this to my list.

Thanks for sharing..

-- Dan ~ Texarkana, Tx.

View Bob Simmons's profile

Bob Simmons

505 posts in 3039 days

#6 posted 11-16-2011 01:01 AM

Dan…Thanks!...Glad to make contact with you again.

With your ingenuity you will find some great uses for the dado sled. It makes quick and easy work of tenons. Once the blade height is properly adjusted to where the tenon fits the mortise, there’s really no need for cleaning up the tenon as in some other tenon cutting techniques. This method can be a great time saver. Once this one checked marked off your list, let me how how it works out for you.

-- Bob Simmons, Las Vegas, NV,

View StumpyNubs's profile


7599 posts in 2825 days

#7 posted 11-16-2011 05:54 AM

I love it when people take the effort to show us something on camera. Great video!

-- Subscribe to "Stumpy Nubs Woodworking Journal"- One of the crafts' most unique publications:

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