Small Painter's Cabinet #4: Cutting the sides to proper dimension

Like I said earlier, I accidentally set up the table saw with a dado blade before I realized that I had neglected to cut the sides to length. Since the template I am using is based on the dadoes being the correct length, I had to remove the dado stack and put in the normal blade.

When I perform cross cuts, I use a sled. This is particularly important when I need to cut many pieces to the same length. Here is a picture of the first side sitting on my cross cut sled. (Note: This is version 2. There are already plans to build a new third version using the Kreg Precision Measuring System. This will be a topic for a new series.)

I have already squared off one edge of the side and am getting ready to cut them all to the same 28 1/2 inch length. I have devised a simple and effective, but time-consuming, method to ensure the cuts are the same. First, I place a thin 1/8 inch piece of plywood on the piece to cut. I then lay a thin piece of 3/4 inch plywood on top of that and clamp the 3/4 inch piece to the cross cut sled. Here is a picture of the pieces in place:

I can then remove the 1/8 inch piece and the attached piece becomes a relatively stable arm that I can then use for a stop block:

Using a square, I attach a stop block at the predetermined length:

History has shown that I tend to rap the wood pieces against the stop block so I have started adding a fourth clamp to the end to make sure that large pieces do not move the stop block when they are set up against it:

Finally, I’m at where I left off the previous blog entry! I use this template to make sure that I cut the dadoes in the same place for each cabinet.

I learned, the hard way, that even a small discrepancy here can lead to big problems. I While this might not be the best method, I cut all of the 4” offset dadoes first, then flip the sides around and cut the 5 1/2” dadoes from the bottom, and lastly flip the sides a third time and cut the miiddle dado. Here is a crappy picture of a finished side:

As an aside – Here are two pictures of how I place my hands when cutting these dadoes. Any suggestions on a safer method? I’m always looking for better ways to do things.

I then cut the sides to the correct width. I waited to this stage to eliminate any blowout while cutting the dadoes. I had none, but better safe then sorry.

Next time I will be cutting out the legs…

-- "Measure Twice, Cut Once" --- If only I could remember this!