I'm attempting to cut a 1/4" dado using my dado blade set, but I've encountered an issue. Although the minimum stated width is 1/4", my calipers suggest it's measuring more like 5/16" or possibly even 9/16" when checking tooth to tooth. This means the piece of wood I'm trying to inset will fit quite loosely. I tried a test cut and it confirmed my worries. I wonder if my only option is to make two passes with a regular blade to reach the correct width? I've scoured Amazon for a 1/4" kerf table saw blade, but the widest I've found is 0.140", which seems unusual. I have several dados to make, and doubling the time with two passes for each one sounds daunting.
4 Answers
If it’s just a few cuts, going for two passes with a regular blade is probably your simplest solution. But if you're working on a ton of cuts, have you thought about using a router table? It can save you a lot of time in the long run!
For the most precise cuts, consider a dedicated box joint set from brands like Ridge or Forest. They usually have a two-blade stack that can give you a solid 1/4" cut and a nice flat bottom!
Make sure your dado blades are installed properly. Sometimes the teeth can be misaligned if they’re flipped left and right. They should overlap towards the inside of the dado for a clean cut. Also, don’t forget most plywood is under-sized, which can affect how well the piece fits.
Check that the right face is facing outwards before you start cutting, and that none of the blades are hitting each other. When aligned correctly, dado sets really should give you the right width, even if the tooth measurements seem off.
Totally agree! The router table can really speed things up if you have a lot to do.