A while back I wrote an article about how to build a dado cutting jig for your Plunge Router
The key to this jig is to make sure that the two side pieces are VERY square to the third side when you screw them together. If the sides are not square you’ll never be able to cut perpendicular dados in the work piece. I used a countersink pilot drill so that the permanent screws are all recessed below the surface.
Most plywood is not exactly the thickness that you call it. For instance, 3/4″ plywood is actually 23/32″. So if you want a nice tight fit on the slots you need to cut 23/32″ wide dados not 3/4″. For more information on plywood thicknesses check out: Thickness Of Plywood Panels.
It’s as simple as that. Stay tuned for a future post on building the book case.
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Thanks for posting the tips on how to cut dados with a router...these construction tips on how to use drills, augers, edgers, trimmers, and chain saws are extremely helpful.
Thanks.
Great Jig, everyone should have one of these hanging on the wall of the shop. Sometimes they will sit there collecting dust for a year and then all of the sudden you will use it for three weeks straight. I have found that routers with a flat side on the base plate work best with home made jigs. There are a number of companies that make this very version in a commercial brand, but you can save a lot of money making one yourself.