Diablo Stacked Dado Set

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Forum topic by rlrjr posted 07-06-2011 04:27 PM 7791 views 1 time favorited 3 replies Add to Favorites Watch
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65 posts in 2833 days

07-06-2011 04:27 PM

Good morning all;

I just bought the Diablo Stacked Dado Set and I’m going to feel a lot better about this if someone who has experience with stacking these blades explains the procedure.

I’ve put the left outside blade onto the arbor first with the rotation in the right direction.

Then I put one of the chippers on next. The instructions said to place it so that it rests between “the two spaces”. I’ve placed the blade so that the teeth are between the teeth on the left outside blade. Teeth placed in the right direction. (There seems to be a protrusion on the chipper blade that stops it from rotating around on the arbor and striking the teeth on the left outside blade.)

Then I placed another chipper blade next to the previous chipper blade and rotated it 90 degrees (by eye) to the other chipper blade. (These two chipper blades do not have any protrusions and when loose could rotate and strike the teeth on the other chipper blade.)

Then I put on the right outside blade, then the washer and then the nut. The nut, when tightened fully, has the arbor protruding outside about 1/16”—- 1/8”.

According to the chart that came with the blades this should provide a 1/2” cut. I have not installed any spacers in this setup.

Does this sound like the correct way to position the blades to each other? Also, this is an 8” blade set, whereas the other blades I have are 10” blades. The saw is a Rigid TS3650. Some research on the web indicated that 8” blades are correct because they contain less steel and therefore less drag on the motor to keep them spinning at the appropriate RPM’s.

I have a spare, new throat plate. Do I cut the opening in the same manner as you would do with a single 10” blade? (Placing a piece of wood over the blades, clamping them down and then slowly raising the dado set to cut the opening?)

I’m not plugging the saw in or turning it on until I hear a response from someone.

Thanks, Rick

-- When I works, I works hard. When I sits, I sits loose. And when I thinks I falls asleep.--

3 replies so far

View CharlieM1958's profile


16274 posts in 4212 days

#1 posted 07-06-2011 04:38 PM

Everything sounds fine, Rick. (I have the exact same saw, by the way.)

Dado sets usually come in 6” or 8”. Actually, 6” was my choice because this is a relatively low-power saw, but an 8” set will work fine.

As far as I know, the main issue with aligning the blades and chippers is just to be sure to offset the teeth from the adjacent blade so that the carbide tips don’t but together and keep the blades themselves from fitting together tightly. (And of course you want all blades pointing in the right direction.)

Cutting a zero clearance insert is done the same way as for a regular blade. Actually, I just use the stock insert when I use my dado set and it works just fine.

-- Charlie M. "Woodworking - patience = firewood"

View TomHintz's profile


207 posts in 3392 days

#2 posted 07-06-2011 06:17 PM

Stacked dados can have a bit of personality in that a given setup might cut just a tick under or over what you expect. That’s why so many come with shims so that you can tweak it to get the fit that you want. I have a story on using stacked dados at the link below. It has been so popular over the years that I updated it with new photos and video not long ago.

-- Tom Hintz,

View ChrisForthofer's profile


150 posts in 3061 days

#3 posted 07-06-2011 07:10 PM

I have the exact setup you describe, right down to the same model of saw. I can tell you that everything you are planning and have done appears to be safe and sane in my book. The saw is a little underpowered for an 8” (I also have the 8”) set but I have never had an issue with stalling in the cut as long as you feed the board at a reasonable rate. Make sure you lock your blade height once you have the depth you need as the dado’s vibrate a little more than a standard blade and it will change mid cut slightly if the lock thumbscrew isnt tight.


-- -Director of slipshod craftsmanship and attention deficit woodworking

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