Rabbets and Dadoes Oh My... - Woodworking Talk

Tom5151 · 02-17-2009, 12:18 PM

Hello,

I am building a wall mounted garage workbench. I am using 2X4 for the table top frame. I am making a simple frame and joining 2 - 8 foot long sections of 2X4 with a few shorter 18 inch sections of 2X4 as cross members to form a long rectangular box. (additional cross members will need dadoes). I’d like to know the best way to make a rabbet on the end of an 8 foot long 2X4. I’d also like to make a dado at the halfway point of the forward 8 foot section so that I can insert the middle 2X4 leg support on the inside of my frame. Router table would not be safe. Table saw and a dado blade with an 8 foot board would be very clumsy. I am thinking a router and straightedge? Or would it be best to hand cut it?

Also is there a general rule of thumb for how deep a rabbet/dado should be? I know it needs to be as wide as the piece it will receive but is there a general rule of thumb for depth? So for example I want to cut the rabbet on all four ends of the 2 - 8 foot long sections of 2X4. I know the rabbet has to be 1.5 inches wide to accept the width of the 2X4 cross member but how deep should it be? Would ¾ inch be too deep?

Thanks,
Tom

BHOFM · 02-17-2009, 12:58 PM

Router with a clamped on straight edge would be
the best and safe way.

For the cross members I would do a 1/2 dado..
That leaves an inch for the strength of the frame.

Lay the front and rear member of the bench out
and clamp them and cut the rabbits for the ends
and the dados for the cross members in both
pieces at the same time. This will give you an accurate
result.

I would cut the dado in the leg, not the frame so
the frame will sit on top of the dado for support.

Is this another final question???

Tom5151 · 02-17-2009, 01:02 PM

Quote:

Originally Posted by BHOFM

Router with a clamped on straight edge would be
the best and safe way.

For the cross members I would do a 1/2 dado..
That leaves an inch for the strength of the frame.

Lay the front and rear member of the bench out
and clamp them and cut the rabbits for the ends
and the dados for the cross members in both
pieces at the same time. This will give you an accurate
result.

I would cut the dado in the leg, not the frame so
the frame will sit on top of the dado for support.

Is this another final question???

LOL....no way......the FINAL question was only for the Table. As far as the workbench goes there will be many more......

So if I clamp the 2 8 foot sectioins and do them both at one time I should work from the outside in so the router base plate is always supported? I guess I only need the straightedge for the innermost edge of the rabbet, right?

Sorry for the dumb questions but I really am new at this....LOL

Tom5151 · 02-17-2009, 01:11 PM

Quote:

Originally Posted by BHOFM

Router with a clamped on straight edge would be
the best and safe way.

For the cross members I would do a 1/2 dado..
That leaves an inch for the strength of the frame.

Lay the front and rear member of the bench out
and clamp them and cut the rabbits for the ends
and the dados for the cross members in both
pieces at the same time. This will give you an accurate
result.

I would cut the dado in the leg, not the frame so
the frame will sit on top of the dado for support.

Is this another final question???

Oh and i am assuming glue and screw everthing as well?

BHOFM · 02-17-2009, 06:05 PM

In the ones that show, I would counter sink the screws
and put dowel on top, the name for this is bunging.
On at least on boats we bung the screw holes.

Tom5151 · 02-17-2009, 06:07 PM

Quote:

Originally Posted by BHOFM

In the ones that show, I would counter sink the screws
and put dowel on top, the name for this is bunging.
On at least on boats we bung the screw holes.

Dang...before you know it I am going to be a real woodworker......LOL........I have sooooooooooooooooo much to learn......