Help with first project please

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Forum topic by 0bserver posted 02-26-2014 12:09 AM 1095 views 0 times favorited 9 replies Add to Favorites Watch
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3 posts in 1790 days

02-26-2014 12:09 AM

Topic tags/keywords: help project 4100 5625 saw bookcase first question

Hey guys,

I am trying to start simple and designed a bookshelf in sketchup to build in my garage. I sourced some 3/4 birch plywood and I would like to use stopped dados to hold the shelves. I have just starting puting together my woodworking tools and am hoping to get some advice on workflow. I have all the basic hand tools as well as a Bosch 4100 saw and a Milwaukee 5625 router that I have not purchased accessories for yet. I dont mind buying them if that is the easiest way to go. I tried setting up the freud dado set on the 4100 and it was just too clumsy to slide the 60” long panel across the 4100 with no real sled, feather board or assisstance holding the majority of the weight hanging off the saw. I am taking a step back to reconsider which tool and how to use it for this process.

My question is

What method would you recommend for me to cut stopped dados in large panels on the Bosch 4100 Worksite saw or with a Milwaukee 5625 router? .

9 replies so far

View AandCstyle's profile


3185 posts in 2496 days

#1 posted 02-26-2014 12:44 AM

I would use the router for stopped dados, then clean up the corners with the appropriate size chisel. In this case you will need a 5/8” chisel because the 3/4” plywood isn’t really 3/4” wide. You will also need a straight edge clamped to the workpiece to guide the router. Make multiple passes (maybe three) to reach your desired depth (maybe 3/8”). Also, be aware that plywood will sag. You can use the Sagulator to estimate how much. If you add a strip of hardwood to the front edge, it will greatly improve the rigidity of the shelf and looks better than having the edge of the ply show. HTH

-- Art

View graywolf's profile


65 posts in 2932 days

#2 posted 02-26-2014 01:02 AM

+1 on the router with the straight edge. Good luck and post some pics as you go and as you finish

-- Richard, North Carolina,

View 0bserver's profile


3 posts in 1790 days

#3 posted 02-26-2014 01:26 AM

Thanks for the tips!

Wood poplar be a good choice for the edges? I could use it to flush the edge after the dado stops. What bit or bet set should I use for the router? What other accessories would you recommend while I am at it?

View Monte Pittman's profile

Monte Pittman

30151 posts in 2577 days

#4 posted 02-26-2014 01:33 AM

Router. But at some point in the future, practice both ways. Never hurts to learn.

-- Nature created it, I just assemble it.

View AandCstyle's profile


3185 posts in 2496 days

#5 posted 02-26-2014 01:43 AM

Poplar is fine for the edges. It takes paint very well if that is your intent.

There are bits that are sized to plywood. Here is one, but there are probably a million others. Another option is to use a standard size 1/2” router bit and make additional passes to reach the width of your ply. The advantage of this method is that you might not have as much use for the plywood bit as for a standard size bit in the future.

I always buy tools as I need them (actually, I buy them the second time I need them to avoid “one off” purchases). I also do not buy “sets” because you end up paying for sizes you won’t ever use. It sounds like a flush trim bit would be handy for this project. HTH

-- Art

View patron's profile


13641 posts in 3580 days

#6 posted 02-26-2014 01:53 AM

this works great
put some sandpaper on the cheeks that hold the boars
so they don’t slip
a stop if you want it to stop just shy of the front edge
the bit will mark its path on the edge guide rails
so you can align it right
(mark your shelfs on both sides together
and check for square)

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View CrazeeTxn's profile


151 posts in 2189 days

#7 posted 02-26-2014 02:33 AM

Search around here and maybe google for an adjustable dado jig. It will allow you to get the width of the groove based off the actual ply that you have. Then you can use a piloted straight bit or a bushing and make a couple of passes for an almost exact fit.

If you’ve going to put edges on it, you have two choices. You can leave them a little proud of the shelf top and sand flush, but you run the risk of sanding through the ply…or you can also get a flush trim bit.

View Kryptic's profile


294 posts in 1899 days

#8 posted 02-26-2014 03:35 AM

i wouldn’t bother and get it done by a friend with better tools

easier to learn and let yr friends &*^5 it up

View 0bserver's profile


3 posts in 1790 days

#9 posted 02-27-2014 12:45 PM

Thanks guys, I downloaded a template for an adjustable jig and have ordered a flush trim but and the plywood bit. I’ll keep updating as this comes together.

Keep the tips coming.

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