Dadoes

May 25 2014

Part 1
Part 2
Part 3
Part 4
Part 5
Part 6
Part 7
Part 8

Well, I finally got the other three corners done.

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All in all, the rest of the joints turned out well. A few small gaps, but on the whole, I’ve made a lot of progress. There was one tiny bit of splitting, so I had to go back and pare that half pin down just a bit. Should be fine.

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Referring back to the original plan, it’s now time to start prepping the middle divider / handle piece.

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My plan was to just run a 3/16″ deep groove down each of the sides for the handle to slide into. A cross-grain groove like that is known as a dado or a housing dado. If this tote was going to be used for anything heavy, I’d use something stronger, but for pencils and scissors, etc. I think this will be just fine.

First step is to mark out the dado. I made a knife wall on one side of each dado, and a pencil wall on the opposite side as a guide.

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Next, I need to mark the depth of each dado. I do that with a marking gauge. Set it to 3/16″ and scribe a line on each side. This shows me exactly how deep to cut that groove.

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Next up is going to be a bunch more chisel work, so I sharpen those babies up.

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Then, using that knife wall, I start alternately chiseling down and paring away, until I get down to depth on one side.

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With one side chiseled down, I put an actual piece of wood in there and mark the other side with the knife. Then do the same thing on that side. Now I have a groove with a big hump in the center.

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So next up is to reduce that hump a bit with a chisel and get it semi-flat.

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Then I clean it up with a router plane. This is like a short chisel bent 90 degrees stuck in a metal plate. I set it to 3/16″ and use it to completely clean up the bottom of that dado.

 

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With that done, those dadoes are perfectly flat and square, and exactly the right size to fit that center piece. These came out perfect.

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Now I need to make and fit that center piece. It’s got to be taller than the rest of the box, so I had to edge glue a couple of pieces. These are gluing up now, so that finished up my work for today.

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Onto Part 4!

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