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5 Custom Metal Table Saw Blade

5 Custom Metal Table Saw Blade

You apperceive you’re austere about DIY aback you acquirement your aboriginal table saw. To anatomy this amphibian chiffonier you’ll charge a fence and a alliance gauge, which best new table saws appear with.

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Warning: DIY projects can be dangerous, alike for the best accomplished makers. Afore proceeding with this or any added activity on our site, ensure you accept all all-important assurance accessory and apperceive how to use it properly. At minimum, that may accommodate assurance glasses, a facemask, and/or ear protection. If you’re application ability tools, you charge apperceive how to use them cautiously and correctly. If you do not, or are contrarily afflictive with annihilation declared here, don’t attack this project.




Cross cuts and rip cuts

1. Don the able careful gear. That means, at a minimum, assurance glasses and no billowing clothing. I additionally abrasion ear protection, and generally a dust mask, too. This activity makes abundant use of the table saw, which is a able barbarian that deserves the able respect. Accomplish abiding to booty the able precautions aback application it and be acquainted of what can account kickback.

2. Calibrate your alliance gauge. You’ll be application this to accomplish all your cross-cuts (the ones that go beyond the face of the board). Use a carpenter’s aboveboard to accomplish abiding your alliance barometer is as abutting to erect to the saw brand as you can get it. You can additionally spiral a collapsed allotment of “sacrificial” copse to the barometer to extend its ability and advice balance the copse while you cut it.

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3. Cut the four accumbent pieces. The aboriginal three should be about 13 ¼ inches long. The exact breadth doesn’t matter, but what actually does bulk is that they are all absolutely the aforementioned length. We’re talking added absolute than the amplitude of your saw blade, so don’t cut absolutely on the line, cut on one ancillary of the line. I mark which ancillary of the band to cut on with an X. The fourth allotment (the top platform) should be 16 inches long, but attention isn’t as important for this one.

4. Cut the two vertical pieces. These are anniversary 6 inches long. Again, exact breadth doesn’t matter, but they charge to bout anniversary added altogether or you’ll end up with a avant-garde art anatomy rather than a nice aboveboard cabinet.

5. Let ‘er rip. A rip cut is one that is in the aforementioned administration of the atom (down the breadth of the board). Ditch the alliance barometer for now and use the table saw fence to rip two of the 13 ¼-inch boards and the two 6-inch boards bottomward to 4 ½ inches wide. Afresh rip the aftermost 13 ¼-inch lath to 3 ½ inches wide. That aftermost one will be the average shelf, which has to be narrower because there will be a plywood console inset 1 inch from the aback of the cabinet.

Get adequate with some dados

6. Mark the vertical pieces. You’re activity to cut some notches in the two vertical pieces, central of which the accumbent pieces will fit snugly. These are alleged “dados” aback they are aggressive beyond the grain, “grooves” aback aggressive forth the grain, and “rabbets” (or “rebates”) aback they are accessible on one side. You’ll charge to cut two dados and four rabbets for this project. They’ll charge to be absolutely advanced abundant to fit the accumbent boards, and any gaps will be awful arresting in the end product. Mark one of the vertical pieces, afresh sandwich it abutting to the added to alteration your curve over. I chose to accomplish the average shelf hardly aloft the midpoint, for no accurate reason.

7. Cut the dados and rabbets. If you don’t accept a “dado stack” (essentially a absolutely advanced saw brand that ability not alike be acknowledged area you live), you can cut a dado by blurred the saw brand to about bisected the array of the board, afresh demography assorted passes with your alliance barometer while affective the lath hardly to the ancillary amid anniversary pass. Start by acid the dados and rabbets hardly too attenuated and testing the fit. Slowly cut them added and added until the accumbent pieces fit afterwards any jerk room.

8. Cut a canal for the plywood. The plywood abetment will fit central a connected canal active forth the central of the top and basal accumbent pieces, as able-bodied as the two vertical pieces. Lower the acme of the saw brand a little further, to about a division of the array of a board. Application the rip fence again, booty one canyon with the brand a ¾ inch from the fence on all four pieces, afresh move the fence hardly further from the brand and booty another. Test the amplitude to accomplish abiding the plywood will fit. Exact fit doesn’t bulk much, so a little jerk allowance is OK.

9. Booty a footfall back. Except for acid and applicable the plywood backing, the anatomy of the chiffonier is done. Dry-assemble aggregate you accept so far to accomplish abiding all the grooves, dados, and rabbets are in the appropriate place.

Prepare for final cement up

10. Cut the plywood backing. With the chiffonier dry-assembled, admeasurement your chiffonier for the admeasurement of the plywood backing. It should be big abundant to fit aural the groove, but not so big that it prevents the dado and carving joints from applicable together. It doesn’t accept to be an exact fit; it aloof needs to be big abundant to be trapped aural the canal aback the chiffonier is alert up. My console was 12 ¾ by 4 ¾ inches. You will charge to accomplish one rip cut (using the fence) and one cantankerous cut (using the alliance gauge) for this.

11. (Optional) Beach any autogenous surfaces. If there are any imperfections on the autogenous surfaces, you should get rid of them now with some sandpaper amid 80 and 150 grit. These surfaces will be adamantine to ability afterwards you cement aggregate together.

12. (Optional) Stain the plywood. If you plan on staining the final product, now is a acceptable time to stain the plywood backing, too. Or you can balloon like I did and attack to stain it afterwards assembly.

13. Get accessible to glue. Afterwards dry-assembling aggregate to accomplish abiding things are applicable nicely, lay aggregate out in a analytic way and anticipate through the accomplish you will booty to cement it together. You’re activity to cement aggregate calm except the actual top console (the 16-inch-long one) at once. Depending on the blazon of cement you use and the ambient temperature, you may not accept abundant time to dawdle.

14. Glue. Abode a attenuate band of cement in all the dados and rabbets. You won’t charge too abundant if your joints are tight. Ideally, a tiny bulk of cement will clasp out afterwards all the clamps accept been applied. You’ll charge to apple-pie up any cement that does clasp out, either by wiping it anon with a wet rag or abrading it off afterwards a few account (but afore it dries completely). You can cement the plywood into its groove, but accomplishing so is optional; it’ll break in the bracken on its own. Administer a appropriate bulk of burden with the clamps to accomplish abiding there are no gaps in your joints while the cement dries, but don’t go overboard—too abundant burden can able the copse or leave dents in the copse (especially for softer dupe like pine). Accomplish abiding to delay at atomic an hour for the cement to dry afore removing clamps (longer if it’s algid in your workshop).

15. (Optional) Analysis your angles. If you accept a square, it’s acceptable to analysis aggregate afore the cement dries. However, the plywood abetment will anticipate the chiffonier from accepting too skewed, so this footfall is optional.

Final steps

16. Cut the French cleat. The way this chiffonier “floats” on a bank is via a hidden French cleat. Rip and bisect a allotment of actual barge to 12 by 3 inches, afresh bend your table saw brand to 45 degrees and rip it almost bottomward the average (exact bend and abstracts don’t bulk abundant here), creating two cleats. One block will be absorbed to the cabinet, and the added will be absorbed to the wall. This way, you can artlessly lift the chiffonier on and off of the wall.

17. Cement the block to the plywood backing. Administer some cement to the central of one block and abode it on top of the plywood backing. Grab some abundant stuff—I acclimated a car jack and a block of metal—to authority it in abode for at atomic an hour while the cement dries.

18. Pre-drill holes for the bank bisected of the cleat. On the actual cleat, pre-drill two or three holes for screws to attach it to the wall. Pre-drilling is all-important because oak is a adamantine copse and will breach if you attack to drive a spiral beeline through it.

19. Cement on the top. The aftermost footfall in the accumulation is gluing on the top, afresh application either some abundant being or some clamps to authority it on while the cement dries. Accomplish abiding the aback of the top is even with the aback of the cabinet. It should overhang about 1 inch on the two abandon and on the front.

20. (Optional) Beach and administer stain. Now is a acceptable time to beach the alfresco faces of the chiffonier if you so desire. At minimum, I acclaim agilely sanding all the edges to accomplish the chiffonier added adequate to hold. It’s claimed alternative if you appetite to acrylic or stain this cabinet, too. I activated Minwax “espresso” stain to mine, afterward the instructions on the packaging. Afterwards that dried, I activated a few coats of spray-on bark for a careful finish. There are actually absolute textbooks adherent to copse finishes, but my claimed go-tos are spray-on bark or wipe-on polyurethane.

21. Add some hooks to the bottom. Analogously amplitude three hooks and pre-drill holes for them on the basal of the cabinet.

22. Hang the cabinet. Unless you’re planning to angle on this chiffonier yourself, you won’t charge to attach it to a stud in your wall. I acclimated three analogously spaced drywall anchors. Spiral the block to the bank and artlessly abode the chiffonier assimilate it. It floats!

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