Instructions for Making a Dado Sled
Contents
1. ever have any questions regarding your blade please call Freud Customer Service at 800 472 7307 In Canada call 800 263 7016 e Keep these warnings and instructions in a safe place for future reference e Para obtener una copia de estas advertencias en espanol llame 800 472 7307 CREATING A DADO SLED NOTE This is just one of many different ways that woodworkers can create their own dado sled Main Fence 1 STEP 1 Cut all parts to size 3 4 x 4 x 26 taking care to ensure that all i Poly carbonateisatety pieces are square and true 1 2 a N 1 236 x6 x 16 thick plywood is recommended for the main base and hard wood for the other parts The base dimensions may need to be increased or decreased depending on your saw Make sure the runners are a suitable size for the miter gauge slots of your table saw Fence Supports 2 3 4 x 2 x 4 Support Block 1 a 4 4 4 6 Support Block 1 pa 4 gu b4 6 Main Base 1 1 2 x 18 x 26 Runners 2 3 8 x 3 4 x 18 FIGURE 1 FIGURE 3 STEP 2 Place the runners in the miter gage slots of your table saw Make sure they slide freely and have no sideways movement STEP 3 Lay the plywood base on the runners and using the fence make sure the base is parallel to and centered over the runners STEP 4 Drill countersink and screw the base onto the runners Use flat head wood screws that do not protrude through the runners Make sure2. the base fully contacts the saw table and that the assembly slides freely figure 2 STEP 5 Install the dado throat plate on the table saw and mark the location of its opening on the main base to indicate where the dado cut will be made STEP 6 Assemble the dado sled ensuring that the main fence is exactly 90 degrees to saw table fence Center the support blocks over the path of the dado cut Use glue and wood screws to secure the support blocks and fence supports to the main base NOTE Countersink all screws and take care not to place any screws in the path of your intended dado cut Screws may damage the carbide teeth FIGURE 5 STEP 7 Using pan head screws attach the polycarbonate safety guard above the dado slot as shown in figure 5 STEP 8 Disconnect the power from the saw and install the dado cutter set to its maximum cutting width Always check the saw s owner s manual for the maximum allowable dado width STEP 9 Adjust the dado cutter height to 1 4 place the sled in the miter gauge slots reconnect the power and make a dado cut the full length of the sled Disconnect the power remove the sled and raise the dado cutter another 1 4 Reinstall the sled on the saw reconnect the power and make another cut Repeat this procedure a third time to finalize your sled figure 5 An indexing fence is a simple useful addition to a dado sled Use an indexing fence to create joints such as
3. SAFETY INSTRUCTIONS Woodworking projects can be fun and rewarding however your first concern must always be safety Please read and follow the safety instructions detailed below before commencing any woodworking project Z WARNING Failure to obey these warnings could lead to serious bodily injury or death e Read and obey all warnings and instructions contained in the saw machine s user s manual and for any accessory that is from the manufacturer before using the cutter Be sure that this cutter is compatible with your saw machine If you do not have the user s manual obtain one from the machine s manufacturer before using cutter e Only operate saw machine when proper saw guards and protections are in place and working properly e Always wear proper eye protection complying with current CSA standard 294 1 or ANSI Standard Z87 1 and hearing protection e Disconnect saw from the power source when changing removing or adjusting any blades and use caution in handling the dado cutters during installation e Carbide is a very hard and brittle material Slight shocks can damage the carbide Before each use check that the cutter is sharp and free from cracks loose teeth missing teeth broken teeth or any other damage Do not use if the cutter is dull or any damage is noticed or suspected e Use the cutter only for cutting wood Do not use for cutting metal masonry or concrete e Never use cutter in the vicinity of small children e Be sure
4. box joints or to create decorative effects such as dentil molding FIGURE 7 STEP 1 Cut a piece of 3 4 thick wood to 4 x 24 and drill indexing holes as desired Only one 1 4 hole near the center of the board and 1 4 from the bottom edge is required but evenly spaced holes approximately 1 1 2 apart figure 6 will allow for more possible applications for the indexing fence STEP 2 Cut a piece of 1 4 diameter dowel approximately 1 1 2 long Check the fit of the dowel in the hole s and adjust the diameter of the dowel with light sanding if required so that it firmly fits into the holes STEP 3 Using 2 G clamps attach the indexing fence to the main fence of the dado sled as shown in figure 7 The position of the indexing fence can be adjusted to suit the project or cut on which you re working CREATING A PUSH STICK STEP 1 Photocopy this image at full scale OR print g Ae 8 5 copy from the Pdf decumentthatHi Fi y located on the Dado Tips amp Tricks disc e Y a gw a it onto a 1 2 th lt i gf Ff in_lined up_as_indicated Do_nc we je J f splitting or checking af yoy we Ff Y i ew amp J rd d i a i 7 y J y r J y 4 7 J e i a F y P K POPULAR DADO CUTS Below are some of the most popular joints and cuts that can be quickly and easi
5. ly created using Freud dado sets Half Lap Joints Dentil Molding Tenons Corner Lap Joints Box Joints To find out more about Freud products or to order a catalog visit www freudtools com Freud America Inc 1 800 472 7307 U S 1 905 670 1025 Canada 2005 Freud America Inc No portion of this piece may be reprinted without the written consent of Freud America Inc The color Red on router bits and saw blades is a US Registered Trademark of Freud America Inc
6. to keep hands and fingers a safe distance away from the blade while it is turning and wait until the blade stops completely and the saw is disconnected from the power before handling e Keep body clothing and hair clear of spinning blade Do not wear jewelry while operating cutter Keep hands away from cutter and cutting area Never perform operations freehand e Mount cutter securely in proper rotational direction indicated on the face of the blade itself e Never use cutter in the saw machine that will exceed maximum recommended blade RPM indicated on the cutter e Make sure the saw is properly tuned in good working order and that the blade rotates freely within the saw before connecting the saw to the power supply e Clean Well Be sure all components are clean and free from dust and chips Chips between components may affect performance and damage tools e Be sure to obtain the proper insert or throat plate for your saw for dado cutters e Allow saw to reach full soeed before cutting e Always use both outside blades of the dado set Never use the chippers by themselves or with only one outside blade Not using both outside blades can cause personal injury or damage to the tool e When making wide and or deep dado cuts always remove the material in several shallow cuts Doing so will result in a cleaner cut and help reduce the chance of kickbacks e Use caution when handling the dado cutters during installation or adjustments e f you
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