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Old 12-05-2009, 10:49 AM   #1
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Rabbeting large pieces on small table saw


This is the deal. I need to cut rabbets in the edges of pieces of 3/4" plywood but I do not have a router. I can probably get an inexpensive dado set. The problem is I can't use the fence because the pieces overhang my tiny saw table's edge.

What if I tack a cleat on the surface (call if surface A) parallel to the edge being rabbeted and place the material with the cleat hanging down below the surface of my saw's table. In effect, will the cleat act like a fence? (The overhang won't be so much that it will make the piece unwieldy.)

Should this work?

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Old 12-05-2009, 10:57 AM   #2
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Rabbeting large pieces on small table saw


don't see why not, just be careful with a piece that large. i do rabbets on my little table saw most every day!

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Old 12-05-2009, 02:50 PM   #3
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Rabbeting large pieces on small table saw


Sounds like a dangerous operation in which the dado blade will rip the plywood out of your hands and send it flying through the air. Handling large pieces of plywood on a small saw is dangerous. It can be done, but if you are a DIY, you will need to be especially careful. A router or sliding table would be the tools of choice for this operation.
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Old 12-05-2009, 08:59 PM   #4
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Rabbeting large pieces on small table saw


You guys are more than right about being careful with table saws, especially if you are wrestling unwieldy material. I have never used a dado, but thinking of it I can see how it could grab a piece of plywood with incredible torque. Fortunatley for my pocket book I won't have to risk using one. I made a test cut on 2' square piece of 1/2" plywood scrap and it did a pretty fair job of cutting a rabbet along the edge. Of course when I went to by the plywood a guy with whom I was discuusing the plans with in the Lowes hardware department recalled where he had just seen some similar but better plans. So now I bought the 2009 Tools and Shops annual issue of Fine Woodworking Tools and Shops and have to decide which miter saw stand to build.

Of course after buying the pulp rag for $8 bucks I see I could have read the article for free online with a trial subscription. If you want to see what it is like, it's at http://www.finewoodworking.com/Proje....aspx?id=33070
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