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Dado sled

Project by RusticElements posted 430 days ago 1963 views 4 times favorited 14 comments Add to Favorites Watch

Well, after dadoing enough pieces for 3 beehives (96 pieces, dadoed both ends), I discovered my jig (which had to be set for each batch) was out ~1/64”. After 5 dados on each piece that makes the measurement out 5/64”, over 1/16”! Needless to say they didn’t fit together very well. I managed to make short pieces out of the long ones but over all, 3/4 of ~$150 worth of wood is now on the burn pile.

So I thought it was about time I made something that I didn’t have to set every time and take the chance of the measurements being out. So, behold, my new dado sled. It will accommodate up to 7 pieces up to 10 1/2” wide. It’s not adjustable, although the plate with the red and blue marks on it could be replaced for a different measurement. Since this is a dedicated unit I never have to change the measurements, thus never making the previous mistake again (I hope ;)).

There’s a little tear out on the last piece but that can be put inside the hive and be out of sight. Having so many pieces stacked together prevents tear out on the vast majority.

It’s all made from material I had laying around. The sled runners (I know there’s a proper name, I don’t know what it is) are red oak, the rest is 3/4 ply. The plates are 1/8” aluminum. I drilled the marked plate on my milling machine so the measurements are dead accurate. Placing the pin (on the front box) in the holes with the red marks will make the side pieces and the blue marks will make the end pieces.

I plan on ordering a couple of suitable jig clamps to mount on the front and side to hold the wood in place, but a bar clamp and wedge will have to do for now.

-- Michael R. Harvey - Brewster, NY - RusticElementArt.com - SpaceAware.org - AnConn.com


14 comments so far

View sIKE's profile

sIKE

1094 posts in 648 days


posted 430 days ago

Forgive me, it might be that I just woke up, but how does this sled work to make dadoes? Looks like you are cutting end grain, and I thought a dado was a wide cut cross grain….

-- //FC - Round Rock, TX - "Experience is what you get just after you need it"

View RusticElements's profile

RusticElements

166 posts in 620 days


posted 430 days ago

Well this certainly shows my vast expertise doesn’t it?!? I guess I’m not cutting dados, I’m using a dado blade to cut finger joints.

Thanks for the correction. I’ll get this wood working lingo down yet ;).

-- Michael R. Harvey - Brewster, NY - RusticElementArt.com - SpaceAware.org - AnConn.com

View Dominic Vanacora's profile

Dominic Vanacora

504 posts in 764 days


posted 430 days ago

Well your ingenuity is showing. You had a problem and you sloved it. A rose is still a rose no matter what you call it.

-- Dominic, Trinity, Florida...Lets be safe out there.

View Christopher's profile

Christopher

563 posts in 814 days


posted 430 days ago

Dude, this is a great idea!

-- "That Government is Best that Governs The Least."-Jefferson

View Gary's profile

Gary

444 posts in 1218 days


posted 430 days ago

Michael,

I’m still confused; I don’t see how that jig helps you make box (finger) joints.
When making said joint, there’s got to be a way to move the board an exact fixed distance sideways
repeatedly to make the sequential cuts. Google “Lynn’s Box Joint Jig” and you’ll see what I mean.
The one place I could see the jig you’re showing as being useful is for the inner cover as seen in this PDF file:
Plan

Hope that’s useful,
Gary

-- Gary, Florida

View 3fingerpat's profile

3fingerpat

907 posts in 562 days


posted 430 days ago

Gary,
There are pre-drilled holes in the metal plate that is attached to the sled, the box that holds the wood to be cut also has a metal plate with pins. That is how the box gets moved over at a set distance.

Mike, great idea making a jig to fill your specific needs.

-- "You get what you inspect, not what you expect"

View woodspyder's profile

woodspyder

59 posts in 524 days


posted 430 days ago

Michael
It looks to me like you lift the whole box containing the pieces being cut and move it over, using the aluminum as your guide is that correct.
Either way great idea!

-- Measure three times, cut twice.

View Gary's profile

Gary

444 posts in 1218 days


posted 430 days ago

Pat,
I get it now; the first picture is loaded with boards but not loaded as it’s used. That’s partly
what was confusing me.
Good idea Michael—Mass production at its finest.
Gary

-- Gary, Florida

View John Gray's profile

John Gray

1753 posts in 780 days


posted 429 days ago

Still no comprehende.

-- Only the Shadow knows....................

View Grumpy's profile

Grumpy

14920 posts in 745 days


posted 429 days ago

Nothing like a top jig Michael.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View RusticElements's profile

RusticElements

166 posts in 620 days


posted 429 days ago

Ok, to help explain how this contraption works…
Video
My camera stopped recording after 2:45 but it shows enough to get the general idea.

-- Michael R. Harvey - Brewster, NY - RusticElementArt.com - SpaceAware.org - AnConn.com

View Dick, & Barb Cain's profile

Dick, & Barb Cain

7036 posts in 1194 days


posted 429 days ago

Pretty neat. Good thinking!

After seeing the video, it cleared things up for me.

-- -** You are never to old to set another goal or to dream a new dream ****************** Dick, & Barb Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1

View sIKE's profile

sIKE

1094 posts in 648 days


posted 429 days ago

Ahh! I get it! It’s a mass production box joint jig!

-- //FC - Round Rock, TX - "Experience is what you get just after you need it"

View Bureaucrat's profile

Bureaucrat

7236 posts in 546 days


posted 429 days ago

Thanks for the video. That really cleared it up for me. Neat idea!

-- Gary, South Central Wisconsin. So much to learn, so little time!

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